Ethylene α-olefin/diene interpolymer-substituted carboxylic acid dispersant additives

ABSTRACT

The present invention is directed to an oil-soluble lubricating oil additive comprising at least one terminally unsaturated ethylene/alpha-olefin/diene interpolymer of 300 to 20,000 number average molecular weight substituted with mono- or dicarboxylic acid producing moieties (preferably dicarboxylic acid or anhydride moieties), wherein the terminal unsaturation comprises terminal ethenylidene unsaturation. The mono- and dicarboxylic acid or anhydride substituted interpolymers of this invention are useful per se as additives to lubricating oils, and can also be reacted with a nucleophilic reagent, such s amines, alcohols, amino alcohols and reactive metal compounds, to form products which are also useful lubricating oil additives, e.g., as dispersants.

This is a division of U.S. Ser. No. 08/434,084, filed May 3, 1995, nowU.S. Pat. No. 5,681,799 which is a continuation-in-part of U.S. Ser. No.08/263,291, filed Jun. 21, 1994, now U.S. Pat. No. 5,435,926, which is adivision of U.S. Ser. No. 08/132,028, filed Oct. 5, 1993, now U.S. Pat.No. 5,350,532, which is a division of U.S. Ser. No. 07/984,727, filedDec. 4, 1992, now U.S. Pat. No. 5,266,223 which is a continuation ofU.S. Pat. No. 07/769,041, filed Sep. 30, 1991, now abandoned, which is adivision of U.S. Ser. No. 07/473,624, filed Feb. 1, 1990, now abandoned,which is a continuation-in-part of U.S. Ser. No. 07/226,759, filed Aug.1, 1988, now abandoned.

FIELD OF THE INVENTION

This invention relates to improved oil soluble dispersant additivesuseful in oleaginous compositions, including fuels and lubricating oilcompositions, and to concentrates containing said additives.

BACKGROUND OF THE INVENTION

Ashless nitrogen and ester containing lubricating oil dispersants havebeen widely used by the industry. Typically, these dispersants areprepared from a long chain hydrocarbon polymer by reacting the polymerwith maleic anhydride to form the corresponding polymer which issubstituted with succinic anhydride groups. Polyisobutylene has beenwidely used as the polymer of choice, chiefly because it is readilyavailable by cationic polymerization from butene streams (e.g., usingAlCl₃ catalysts). Such polyisobutylenes generally contain residualunsaturation in amounts of about one ethylenic double bond per polymerchain, positioned along the chain.

The polyisobutylene polymers (PIB) employed in most conventionaldispersants are based on a hydrocarbon chain of a number averagemolecular weight (M_(n)) of from about 900 to about 2500. PIB having aM_(n) of less than about 300 gives rather poor performance results whenemployed in dispersants because the molecular weight is insufficient tokeep the dispersant molecule fully solubilized in lubricating oils. Onthe other hand, high molecular weight PIB (M_(n) >3000) becomes soviscous that conventional industrial practices are incapable of handlingthis product in many operations. This problem becomes much more severeas the PIB molecular weight increases to 5000 or 10,000.

Increased amounts of terminal ethylenic unsaturation in polyisobutylene(so-called "reactive polyisobutylene") has been achieved by BF₃catalyzed polymerization of isobutylene. Exemplary of referencesdisclosing these polymers is U.S. Pat. No. 4,152,499. However, suchreactive polyisobutylene materials can still contain substantial amountsof unsaturation elsewhere along the chain. Further, it is difficult toproduce such reactive polyisobutylene polymers at molecular weights ofgreater than about 2,000, and, even so, the reactive polyisobutylenesthemselves still suffer the above-noted viscosity increase disadvantagesas molecular weights are increased.

Other polymers, such as ethylene-propylene co-polymers and terpolymerscontaining non-conjugated dienes, have been disclosed as suitablepolymers for the preparation of ashless nitrogen and ester dispersants.

U.S. Pat. No. 4,234,435, for example, discloses dispersants preparedfrom polyalkenes, M_(n) of 1,300 to about 5,000. The polyalkene cancomprise homopolymers or interpolymers of C₂ to C₁₆ terminal olefins, ofwhich ethylene-propylene copolymers are said to be examples, withspecific reference to a copolymer of 80% ethylene and 20% propylene.

However, ethylene-alpha-olefin copolymers of the above molecular weightscould be produced using Ziegler-Natta catalysts only in combination withH₂ as molecular weight control in order to terminate the growingcopolymer chains within this molecular weight range. Without use of H₂or other conventional, so-called "chain stoppers", the copolymersproduced with Ziegler-Natta catalysts would tend to have molecularweights greatly in excess of the above range. (Such higher copolymers,for example, are widely employed in ungrafted form as viscosity indeximprovers, and when grafted with nitrogen-containing groups, asdescribed below, are conventionally employed as dispersant-viscosityindex improver polymers.) The use of H₂ as a chain stopper has thedisadvantage of causing the saturation of the olefinic double bondcontent of the copolymer. Thus, while lower molecular weight copolymerswere theoretically possible to prepare, their low unsaturation content(and the accompanying low graft copolymer yields) would have made theirfurther functionalization by a thermal "ene" reaction, e.g., withdicarboxylic acid moieties in preparing dispersants, highlyunattractive.

High molecular weight ethylene-propylene polymers andethylene-propylene-diene terpolymers, having viscosity average molecularweights of from about 20,000 to 300,000, are generally producedemploying Ziegler catalysts, generally VCl₄ or VOCl₃ with a halidesource, such as organoaluminum halides and/or hydrogen halides. Suchhigh molecular weight EP and EPDM polymers find use as viscosity indeximprovers. See, e.g., U.S. Pat. Nos. 3,563,964; 3,697,429; 4,306,041;4,540,753; 4,575,574; and 4,666,619.

The concept of derivatizing V.I. improving high molecular weightethylene copolymers, with acid moieties such as maleic anhydride,followed by reaction with an amine, to form a V.I.-dispersant oiladditive is known in the art as indicated by the following patents.

U.S. Pat. No. 3,316,177 teaches ethylene copolymers of at least 50,000,such as ethylene-propylene, or ethylene-propylene-diene, which areheated to elevated temperatures in the presence of oxygen so as tooxidize the polymer and cause its reaction with maleic anhydride whichis present during the oxidation. The resulting polymer can then bereacted with alkylene polyamines.

U.S. Pat. No. 3,326,804 teaches reacting ethylene copolymers with oxygenor ozone, to form a hydroperoxidized polymer, which is grafted withmaleic anhydride followed by reaction with polyalkylene polyamines.Preferred are ethylene-propylene copolymers, having M_(v) from 100,000to 500,000, prepared by Ziegler type catalysts.

U.S. Pat. No. 4,160,739 teaches an ethylene copolymer (M_(v) =10,000 to200,000) which is grafted, using a free radical technique, withalternating maleic anhydride and a second polymerizable monomer such asmethacrylic acid, which materials are reacted with an amine having asingle primary, or a single secondary, amine group.

U.S. Pat. No. 4,161,452 relates to graft copolymers wherein the backbonepolymer is a polymeric hydrocarbon such as EP copolymer or EPDM (M_(v)=10,000 to 200,000) and the grafted units are the residues of anaddition copolymerizable monomer system comprising, e.g., maleicanhydride, and at least one other addition monomer.

U.S. Pat. No. 4,171,273 reacts an ethylene copolymer (M_(v) =10,000 to100,000) with maleic anhydride in the presence of a free radicalinitiator and then with mixtures of C₄ to C₁₂ n-alcohol and amine suchas N-aminopropylmorpholine or dimethylamino propyl amine to form aV.I.-dispersant-pour depressant additive.

U.S. Pat. No. 4,517,104 relates to EP and EPDM viscosity indeximprover-dispersant additives prepared from EP polymer (M_(n) =5000 to500,000), by maleic anhydride grafting and reaction with polyamines.

The following references include disclosures of EP/EPDM polymers ofM_(n) of 700/500,000, also prepared by conventional Ziegler catalysts.

U.S. Pat. No. 4,089,794 teaches grafting the ethylene copolymer (M_(n)=700 to 500,000) with maleic anhydride using peroxide in a lubricatingoil solution, wherein the grafting is preferably carried out undernitrogen, followed by reaction with polyamine.

U.S. Pat. No. 4,137,185 teaches reacting C₁ to C₃₀ monocarboxylic acidanhydrides, and dicarboxylic anhydrides, such as acetic anhydride,succinic anhydride, etc., with an ethylene copolymer (M_(n) =700 to500,000) reacted with maleic anhydride and a polyalkylene polyamine toinhibit cross linking and viscosity increase due to further reaction ofany primary amine groups which were initially unreacted.

U.S. Pat. No. 4,144,181 is similar to 4,137,185 in that it teaches usinga sulfonic acid to inactivate the remaining primary amine groups when amaleic anhydride grafted ethylene-propylene copolymer (M_(n) =700 to500,000) is reacted with a polyamine.

U.S. Pat. No. 4,219,432 teaches maleic anhydride grafted ethylenecopolymer (M_(n) =700 to 500,000) reacted with a mixture of an aminehaving only one primary group together with a second amine having two ormore primary groups.

Related disclosures of maleic anhydride grafted, aminatedethylene-propylene polymer viscosity improver-dispersant additivesuseful in lubricating oil compositions are contained in U.S. Pat. Nos.4,507,515; 4,557,847; 4,632,769; 4,693,838; and 4,707,285.

U.S. Pat. No. 4,668,834 to Uniroyal Chemical discloses preparation (viacertain metallocene and alumoxane catalyst systems) and composition ofethylene-alpha olefin copolymers and terpolymers having vinylidene-typeterminal unsaturation, which are disclosed to be useful as intermediatesin epoxy-grafted encapsulation compositions.

U.S. Pat. No. 4,704,491 to Mitsui Petrochemical relates to liquidethylene alpha-olefin random copolymers, useful when hydrogenated assynthetic lubricant oil, characterized inter alia by having 10-85 mol. %ethylene units, 15-90 mol. % alpha-olefin units, M_(n) of from 300 to10,000 and a M_(w) /M_(n) of not more than 2.5. The patent alsoindicates that the liquid copolymer can be easily modified since it hasa double bond capable of reacting with maleic anhydride, etc., at themolecular chain ends.

Japanese Published Patent Application 87-129,303A of MitsuiPetrochemical relates to narrow molecular weight distribution (M_(w)/M_(n) <2.5) ethylene alpha-olefin copolymer waxes containing 85-99 mol% ethylene, which are disclosed to be used for dispersing agents,modifiers lo or materials to produce toners. The copolymers (havingcrystallinity of from 5-85%) are prepared in the presence of a catalystsystem comprising Zr compounds having at least one cycloalkadienyl groupand alumoxane.

European Patent 128,046 discloses (co)polyolefin reactor blends ofpolyethylene and ethylene higher alpha-olefin copolymers prepared byemploying described dual-metallocene/alumoxane catalyst systems.

European Patent Publication 129,368 discloses metallocene/alumoxanecatalysts useful for the preparation of ethylene homopolymer andethylene higher alpha-olefin copolymers.

European Patent Application Publication 257,696 A1 relates to a processfor dimerizing alpha-olefins using a catalyst comprising certainmetallocene/alumoxane systems.

European Patent Publication 305,022-A1 to Mitsui Petrochemical relatesto certain synthetic hydrocarbon lubricating oil compositions containinga load-withstanding additive and a liquid ethylene alpha-olefin randomcopolymer modified by graft copolymerization with an unsaturatedcarboxylic acid or derivative thereof (e.g., maleic anhydride). Theethylene alpha-olefin copolymers (M_(n) of 300 to 12,000) are obtainedusing Ziegler catalysts (e.g., catalyst formed from soluble V compoundand an organo aluminum compound), are grafted in the presence of a freeradical initiator.

PCT Published Patent Application WO 88/01626 relates to transition metalcompound/alumoxane catalysts for polymerizing alpha-olefins.

SUMMARY OF THE INVENTION

The present invention is a functionalized polymer comprising anethylene/alpha-olefin/diene interpolymer substituted withmonounsaturated mono- or dicarboxylic acid-producing moieties, saidinterpolymer having (i) monomer units derived from ethylene, at leastone alpha-olefin of the formula H₂ C═CHR¹ wherein R¹ is a C₁ -C₁₈ alkylgroup, and at least one diene monomer; (ii) an M_(n) of about300-20,000; (iii) at least about 30% of its chains with ethenylideneterminal unsaturation; and (iv) less than 5 wt. % polymer fraction ofM_(n) less than about 300:

said functionalized polymer having a VR value of less than about 4.1.

The present invention is an oil-soluble dispersant adduct of: (a) anethylene/alpha-olefin/diene interpolymer substituted withmonounsaturated mono- or di-carboxylic acid-producing moieties, saidinterpolymer having: (i) monomer units derived from ethylene, at leastone alpha-olefin of the formula H₂ C═CHR¹ wherein R¹ is C₁ -C₁₈ alkylgroup, and at least one diene monomer; (ii) a M_(n) of about 300-20,000;and at least about 30% of its chains with ethylidene terminalunsaturation; and (b) at least one nucleophilic reagent selected fromthe group consisting of amines, alcohols, metal reactants, and mixturesthereof.

The present invention is directed to an oil-soluble lubricating oiladditive comprising ethylene alpha-olefin interpolymers of 300 to 20,000number average molecular weight terminally substituted with mono- ordicarboxylic acid producing moieties (preferably acid or anhydridemoieties), wherein the ethylene alpha-olefin polymer group is derivedfrom a terminally unsaturated ethylene alpha-olefin polymer wherein theterminal unsaturation comprises ethenylidene unsaturation. Themonocarboxylic acid and the dicarboxylic acid or anhydride substitutedpolymers of this invention are useful per se as additives to oleaginouscompositions, such as fuels or lubricating oils, and can also be reactedwith a nucleophilic reagent, such as amines, alcohols, amino alcoholsand metal compounds, to form derivative products which are also usefulas additives to oleaginous compositions, such as, e.g., fuel additivesor lubricating oil additives, e.g., as dispersants.

The materials of the invention are different from the prior art becauseof their effectiveness and their ability to provide enhanced lubricatingoil dispersancy, as exhibited by their enhanced sludge and varnishcontrol properties. In fuels, the additives serve to minimize the degreeof carburetor and fuel injector fouling from deposits. In addition, theadditives of this invention possess superior viscometric properties.

The process of this invention permits the preparation of lubricating oiland fuel dispersant additives which are simultaneously characterized bya high active ingredient content (usually at least about 60 wt. %, up toabout 95 wt. %) and by advantageous viscosity properties to permit theadditives to be readily handled. In addition, the ethylene alpha-olefinpolymers substituted by mono- and di-carboxylic acid producing moietiesof this invention can be characterized by VR values (as hereinafterdefined) of not greater than about 4.1, thereby providing advantageousviscosity modifying properties to the lubricating oils containing them.The present invention can produce such substituted polymers in a highlyconcentrated form as substantially halogen free materials, therebyreducing the corrositivity processing difficulties and environmentalconcerns which are associated with halogen-containing lubricating oiladditives.

Further, dispersant materials can be prepared from the substitutedpolymers of this invention to provide fuel and lubricating oildispersant products having VR' values of not greater than about 4.1 andVR'/VR_(r) ratios of less than about 1.11 (as such values and ratios arehereinafter defined). Surprisingly, the process of this inventionpermits the preparation of highly concentrated, substantiallyhalogen-free dispersants from high molecular weightethylene-alpha-olefin polymers (M_(n) >5000, e.g., 5,500-20,000) ofsuperior viscosity properties.

DETAILED DESCRIPTION OF THE INVENTION

Preparation of Ethylene Alpha-olefin Polymer

The polymers employed in this invention are polymers of ethylene and atleast one alpha-olefin having the formula H₂ C═CHR¹ wherein R¹ isstraight chain or branched chain alkyl radical comprising 1 to 18 carbonatoms and wherein the polymer contains a high degree of terminalethenylidene unsaturation. Preferably R¹ in the above formula is alkylof from 1 to 8 carbon atoms, and more preferably is alkyl of from 1 to 2carbon atoms. Therefore, useful comonomers with ethylene in thisinvention include propylene, 1-butene, hexene-1,octene-1,4-methylpentene-1, decene-1, dodecene-1, tridecene-1,tetradecene-1, pentadecene-1, hexadecene-1, heptadecene-1, octadecene-1,nonadecene-1 and mixtures thereof (e.g., mixtures of propylene and1-butene, and the like).

The polymers employed in this invention are also diene interpolymers,especially terpolymers of ethylene, at least one alpha-olefin having theformula H₂ C═CHR¹ wherein R¹ is straight chain or branched chain alkylradical conveniently comprising 1 to 18 carbon atoms, and at least onediene monomer, wherein the polymer contains a high degree of terminalethenylidene unsaturation (in addition to any other unsaturationprovided by diene incorporation). Examples of such polymers areethylene/propylene/cyclopentadiene interpolymers, especiallyterpolymers; ethylene/propylene/5-ethylidene-2-norbornene interpolymers;ethylene/butene/cyclopentadiene interpolymers;ethylene/butene/1,4-hexadiene interpolymers; and the like.

Exemplary of such polymers are ethylene-propylene copolymers,ethylene-butene-1 copolymers and the like. Preferred polymers arecopolymers of ethylene and propylene and ethylene and butene-1.

The molar ethylene content of the polymers employed in this invention ispreferably in the range of between about 20 and about 80 percent, andmore preferably between about 30 and about 70 percent. When propyleneand/or butene-1 are employed as comonomer(s) with ethylene, the ethylenecontent of such copolymers is most preferably between about 45 and about65 percent, although higher or lower ethylene contents may be present.

The diene monomers usable in the invention include the alpha/omegadienes, conjugated dienes, and some non-conjugated dienes. Included are1,4-hexadiene dicyclopentadiene, 5-ethylidene-2-norbornene, vinylnorbornene, methyl hexadiene, and the like in portions up to about 25weight percent of the polymer.

The polymers employed in this invention generally possess a numberaverage molecular weight of from about 300 to about 20,000 (e.g., from300 to 10,000), preferably from about 900 to 20,000; more preferably offrom about 900 to 10,000 (e.g., from about 700 to about 15,000); fromabout 1500 to about 5,000. Polymers having a number average molecularweight within the range of from about 700 to 5,000 (e.g., 1500 to 3,000)are particularly useful in the present invention. The number averagemolecular weight for such polymers can be determined by several knowntechniques. A convenient method for such determination is by sizeexclusion chromatography (also known as gel permeation chromatography(GPC)) which additionally provides molecular weight distributioninformation, see W. W. Yau, J. J. Kirkland and D. D. Bly, "Modern SizeExclusion Liquid Chromatography", John Wiley and Sons, New York, 1979.

Consequently, such polymers generally possess an intrinsic viscosity (asmeasured in tetralin at 135° C.) of between about 0.025 and about 0.9dl/g, preferably of between about 0.05 and about 0.5 dl/g, mostpreferably of between about 0.075 and about 0.4 dl/g.

The polymers employed in this invention preferably exhibit a degree ofcrystallinity such that, when grafted, they are essentially amorphous.

The polymers employed in this invention are further characterized inthat up to about 95% and more of the polymer chains possess terminalethenylidene-type unsaturation. Thus, one end of such polymers will beof the formula POLY-C(T¹)═CH₂ wherein T¹ is C₁ to C₁₈ alkyl, preferablyC₁ to C₈ alkyl, and more preferably C₁ to C₂ alkyl, (e.g., methyl orethyl) and wherein POLY represents the polymer chain. The chain lengthof the T¹ alkyl group will vary depending on the comonomer(s) selectedfor use in the polymerization. A minor amount of the polymer chains cancontain terminal ethenyl unsaturation, i.e. POLY-CH═CH₂, and a portionof the polymers can contain internal monounsaturation, e.g.POLY-CH═CH(T¹), wherein T¹ is as defined above.

The polymer employed in this invention comprises polymer chains, atleast about 30 percent of which possess terminal ethenylideneunsaturation. Preferably at least about 50 percent, more preferably atleast about 60 percent, and most preferably at least about 75 percent(e.g. 75-98%), of such polymer chains exhibit terminal ethyenylideneunsaturation. The percentage of polymer chains exhibiting terminalethyenylidene unsaturation may be determined by FTIR spectroscopicanalysis, titration, or C¹³ NMR.

The polymer and the composition employed in this invention may beprepared as described in U.S. Pat. No. 4,668,834, in European PatentPublications 128,046 and 129,368, and in co-pending Ser. No. 728,111,filed Apr. 29, 1985, and copending Ser. No. 93,460, filed Sep. 10, 1987,the disclosures of all of which are hereby incorporated by reference intheir entirety.

The polymers for use in the present invention can be prepared bypolymerizing monomer mixtures comprising ethylene in combination withother monomers such as alpha-olefins and dienes having from 3 to 20carbon atoms (and preferably from 34 carbon atoms, i.e., propylene,butene-1, and mixtures thereof) and cyclopentadiene, vinyl norbornene,etc. in the presence of a catalyst system comprising at least onemetallocene (e.g., a cyclopentadienyl-transition metal compound) and analumoxane compound. The comonomer content can be controlled through theselection of the metallocene catalyst component and by controlling thepartial pressure of the various monomers.

The catalyst is preferably a bulky ligand transition metal compound. Thebulky ligand may contain a multiplicity of bonded atoms, preferablycarbon atoms, forming a group which may be cyclic with one or moreoptional heteroatoms. The bulky ligand may be a cyclopentadienylderivative which can be mono- or polynuclear. One or more bulky ligandsmay be bonded to the transition metal atom. The transition metal atommay be a Group IV, V or VI transition metal. ("Group" refers to anidentified group of the Periodic Table of Elements, comprehensivelypresented in "Advanced Inorganic Chemistry," F. A. Cotton, G. Wilkinson,Fifth Edition, 1988, John Wiley & Sons). Other ligands may be bonded tothe transition metal, preferably detachable by a cocatalyst such as ahydrocarbyl or halogen leaving group. The catalyst is derivable from acompound of the formula

     L!.sub.m M X!.sub.n

wherein L is the bulky ligand, X is the leaving group, M is thetransition metal and m and n are such that the total ligand valencycorresponds to the transition metal valency. Preferably the catalyst isfour coordinate such that the compound is ionizable to a 1⁺ valencystate.

The ligands L and X may be bridged to each other and if two ligands Land/or X are present, they may be bridged. The metallocenes may befull-sandwich compounds having two ligands L which are cyclopentadienylgroups or half-sandwich compounds having one ligand L only which is acyclopentadienyl group.

For the purposes of this patent specification the term "metallocene" isdefined to contain one or more cyclopentadienyl moiety in combinationwith a transition metal of the Periodic Table of Elements. In oneembodiment the metallocene catalyst component is represented by thegeneral formula (Cp)_(m) MR_(n) R'p wherein Cp is a substituted orunsubstituted cyclopentadienyl ring; M is a Group IV, V or VI transitionmetal; R and R' are independently selected halogen, hydrocarbyl group,or hydrocarboxyl groups having 1-20 carbon atoms; m=1-3, n=0-3, p=0-3,and the sum of m+n+p equals the oxidation state of M. In anotherembodiment the metallocene catalyst is represented by the formulas:

    (C.sub.5 R'.sub.m).sub.p R".sub.s (C.sub.5 R'.sub.m)MeQ.sub.3-p-x

and

    R".sub.s (C.sub.5 R'.sub.m).sub.2 MeQ'

wherein Me is a Group IV, V, or VI transition metal C₅ R'_(m) is asubstituted cyclopentadienyl each R', which can be the same or differentis hydrogen, alkenyl aryl alkaryl or arylalkyl radical having from 1 to20 carbon atoms or two carbon atoms joined together to form a part of aC₄ to C₆ ring, R" is one or more of or a combination of a carbon, agermanium, a silicon, a phosphorous or a nitrogen atom containingradical substituting on and bridging two C₅ R'_(m) rings or bridging oneC₅ R'_(m) ring back to Me, when p=0 and x=1 otherwise x is always equalto 0, each Q which can be the same or different is an aryl, alkyl,alkenyl, alkaryl, or arylalkyl radical having from 1 to 20 carbon atomsor halogen, Q' is an alkylidene radical having from 1 to 20 carbonatoms, s is 0 or 1 and when s is 0, m is 5 and p is 0, 1 or 2 and when sis 1, m is 4 and p is 1.

Various forms of the catalyst system of the metallocene type may be usedin the *polymerization process of this invention. Exemplary of thedevelopment of metallocene catalysts in the art for the polymerizationof ethylene is the disclosure of U.S. Pat. No. 4,871,705 to Hoel, U.S.Pat. No. 4,937,299 to Ewen, et al. and EP-A3 129 368 published Jul. 26,1989, and U.S. Pat. Nos. 5,017,713 and 5,120,867 to Welborn, Jr. Thesepublications teach the structure of the metallocene catalysts andinclude alumoxane as the cocatalyst. There are a variety of methods forpreparing alumoxane, one of which is described in U.S. Pat. No.4,665,208.

For the purposes of this patent specification, the terms "cocatalysts oractivators" are used interchangeably and are defined to be any compoundor component which can activate a bulky ligand transition metalcompound. In one embodiment the activators generally contain a metal ofGroup II and III of the Periodic Table of Elements. In the preferredembodiment, the bulky transition metal compound are metallocenes, whichare activated by trialkylaluminum compounds, alumoxanes both linear andcyclic, or ionizing ionic activators or compounds such astri(n-butyl)ammonium tetra (pentafluorophenyl)boron, which ionize theneutral metallocene compound. Such ionizing compounds may contain anactive proton, or some other cation associated with but not coordinated,or only loosely coordinated to the remaining ion of the ionizing ioniccompound. Such compounds are described in EP-A0520 732, EP-A-0 277 003,and EP-A0 277 004 published Aug. 3, 1988, and U.S. Pat. Nos. 5,153,157;5,198,401 and 5,241,025. Further, the metallocene catalyst component canbe a monocyclopentadienyl heteroatom containing compound. Thisheteroatom is activated by either an alumoxane or an ionic activator toform an active polymerization catalyst system to produce polymers usefulin this invention. These types of catalyst systems are described in, forexample, PCT International Publication WO 92/00333 published Jan. 9,1992, U.S. Pat. Nos. 5,057,475; 5,096,867; 5,055,438 and 5,227,440 andEP-A-0 420 436, WO 91/04257. In addition, the metallocene catalystsuseful in this invention can include non-cyclopentadienyl catalystcomponents, or ancillary ligands such as boroles or carbollides incombination with a transition metal. Additionally, it is not beyond thescope of this invention that the catalysts and catalyst systems may bethose described in U.S. Pat. No. 5,064,802 and PCT publications WO93/08221 and WO 93/08199 published Apr. 29, 1993. All the catalystsystems of the invention may be, optionally, prepolymerized or used inconjunction with an additive or scavenging component to enhancecatalytic productivity.

The mole ratio of aluminum in the alumoxane to total metal in themetallocenes which can be usefully employed can be in the range of about0.5:1 to about 1000:1, and desirably about 1:1 to about 100:1.Preferably, the mole ratio will be in the range of 50:1 to about 5:1 andmost preferably 20:1 to 5:1.

The solvents used in the preparation of the catalyst system are inerthydrocarbons, in particular a hydrocarbon that is inert with respect tothe catalyst system. Such solvents are well known and include, forexample, isobutane, butane, pentane, hexane, heptane, octane,cyclohexane, methylcyclohexane, toluene, xylene and the like.

Polymerization is generally conducted at temperatures ranging betweenabout 20° and about 300° C., preferably between about 30° and about 200°C. Reaction time is not critical and may vary from several hours or moreto several minutes or less, depending upon factors such as reactiontemperature, the monomers to be copolymerized, and the like. One ofordinary skill in the art may readily obtain the optimum reaction timefor a given set of reaction parameters by routine experimentation.

The catalyst systems described herein are suitable for thepolymerization of olefins in solution over a wide range of pressures.Preferably, the polymerization will be completed at a pressure of fromabout 10 to about 3,000 bar, and generally at a pressure within therange from about 40 bar to about 2,000 bar, and most preferably, thepolymerization will be completed at a pressure within the range fromabout 50 bar to about 1,500 bar.

After polymerization and, optionally, deactivation of the catalyst(e.g., by conventional techniques such as contacting the polymerizationreaction medium with water or an alcohol, such as methanol, propanol,isopropanol, etc., or cooling or flashing the medium to terminate thepolymerization reaction), the product polymer can be recovered byprocesses well known in the art. Any excess reactants may be flashed offfrom the polymer.

The polymerization may be conducted employing liquid monomer, such asliquid propylene, or mixtures of liquid monomers (such as mixtures ofliquid propylene and 1-butene), as the reaction medium. Alternatively,polymerization may be accomplished in the presence of a hydrocarboninert to the polymerization such as butane, pentane, isopentane, hexane,isooctane, decane, toluene, xylene, and the like.

In those situations wherein the molecular weight of the polymer productthat would be produced at a given set of operating conditions is higherthan desired, any of the techniques known in the prior art for controlof molecular weight, such as the use of hydrogen and/or polymerizationtemperature control, may be used in the process of this invention. If sodesired, the polymerization may be carried out in the presence ofhydrogen to lower the polymer molecular weight. Care should be taken toassure that terminal ethenylidene unsaturation is not reduced to lessthan about 30 percent of the polymer chains.

However, the polymers are preferably formed in the substantial absenceof added H₂ gas, that is, the absence of H₂ gas added in amountseffective to substantially reduce the polymer molecular weight. Morepreferably, the polymerizations will be conducted employing less than 5wppm, and more preferably less than 1 wppm, of added H₂ gas, based onthe moles of the ethylene monomer charged to the polymerization zone.

When carrying out the polymerization in a batch-type fashion, thereaction diluent (if any), ethylene and alpha-olefin comonomer(s) arecharged at appropriate ratios to a suitable reactor. Care must be takenthat all ingredients are dry, with the reactants typically being passedthrough molecular sieves or other drying means prior to theirintroduction into the reactor. Subsequently, either the catalyst andthen the cocatalyst, or first the cocatalyst and then the catalyst areintroduced while agitating the reaction mixture, thereby causingpolymerization to commence. Alternatively, the catalyst and cocatalystmay be premixed in a solvent and then charged to the reactor. As polymeris being formed, additional monomers may be added to the reactor. Uponcompletion of the reaction, unreacted monomer and solvent are eitherflashed or distilled off, if necessary by vacuum, and the low molecularweight copolymer withdrawn from the reactor.

The polymerization may be conducted in a continuous manner bysimultaneously feeding the reaction diluent (if employed), monomers,catalyst and cocatalyst to a reactor and withdrawing solvent, unreactedmonomer and polymer from the reactor so as to allow a residence time ofingredients long enough for forming polymer of the desired molecularweight and separating the polymer from the reaction mixture.

PREPARATION OF ETHYLENE ALPHA-OLEFIN POLYMER SUBSTITUTED MONO- ORDICARBOXYLIC ACID MATERIAL

The ethylene alpha-olefin polymer substituted mono- or dicarboxylic acidmaterial, i.e., acid, anhydride or acid ester of this invention,includes the reaction product of ethylene alpha-olefin polymer(including diene interpolymers) with a monounsaturated carboxylicreactant comprising at least one member selected from the groupconsisting of (i) monounsaturated C₄ to C₁₀ dicarboxylic acid wherein(a) the carboxyl groups are vicinyl, (i.e. located on adjacent carbonatoms) and (b) at least one, preferably both, of said adjacent carbonatoms are part of said mono unsaturation; (ii) derivatives of (i) suchas anhydrides or C₁ to C₅ alcohol derived mono- or di-esters of (i);(iii) monounsaturated C₃ to C₁₀ monocarboxylic acid wherein thecarbon-carbon double bond is allylic to the carboxy group, i.e, of thestructure ##STR1## and (iv) derivatives of (iii) such as C₁ to C₅alcohol derived mono- or di-esters of (iii). Upon reaction with thepolymer, the monounsaturation of the monounsaturated carboxylic reactantbecomes saturated. Thus, for example, maleic anhydride becomes a polymersubstituted succinic anhydride, and acrylic acid becomes a polymersubstituted propionic acid.

Typically, from about 0.7 to about 4.0 (e.g., 0.8 to 2.6), preferablyfrom about 1.0 to about 2.0, and most preferably from about 1.1 to about1.7 moles of said monounsaturated carboxylic reactant are charged to thereactor per mole of polymer charged.

Normally, not all of the polymer reacts with the monounsaturatedcarboxylic reactant and the reaction mixture will contain unreactedpolymer. The unreacted polymer is typically not removed from thereaction mixture (because such removal is difficult and would becommercially infeasible) and the product mixture, stripped of anymonounsaturated carboxylic reactant is employed for further reactionwith the amine or alcohol as described hereinafter to make thedispersant.

Characterization of the average number of moles of monounsaturatedcarboxylic reactant which have reacted per mole of polymer charged tothe reaction (whether it has undergone reaction or not) is definedherein as functionality. Said functionality is based upon (i)determination of the saponification number of the resulting productmixture using potassium hydroxide; and (ii) the number average molecularweight of the polymer charged, using techniques well known in the art.

Functionality is defined solely with reference to the resulting productmixture. Although the amount of said reacted polymer contained in theresulting product mixture can be subsequently modified, i.e. increasedor decreased by techniques known in the art, such modifications do notalter functionality as defined above. The terms ethylene-alpha-olefinpolymer substituted monocarboxylic acid material andethylene-alpha-olefin polymer substituted dicarboxylic acid material areintended to refer to the product mixture whether it has undergone suchmodification or not.

Accordingly, the functionality of the ethylene-alpha-olefin polymersubstituted mono- and dicarboxylic acid material will be typically atleast about 0.5, preferably at least about 0.8, and most preferably atleast about 0.9 and will vary typically from about 0.5 to about 2.8(e.g., 0.6 to 2), preferably from about 0.8 to about 1.4, and mostpreferably from about 0.9 to about 1.3.

Exemplary of such monounsaturated carboxylic reactants are fumaric acid,itaconic acid, maleic acid, maleic anhydride, chloromaleic acid,chloromaleic anhydride, acrylic acid, methacrylic acid, crotonic acid,cinnamic acid, and lower alkyl (e.g., C₁ to C₄ alkyl) acid esters of theforegoing, e.g., methyl maleate, ethyl fumarate, methyl fumarate, etc.

The polymer can be reacted with the monounsaturated carboxylic reactantby a variety of methods. For example, the polymer can be firsthalogenated, chlorinated or brominated to about 1 to 8 wt. %, preferably3 to 7 wt. % chlorine, or bromine, based on the weight of polymer, bypassing the chlorine or bromine through the polymer at a temperature of60° to 250° C., preferably 110° to 160° C., e.g., 120° to 140° C., forabout 0.5 to 10, preferably 1 to 7 hours. The halogenated polymer maythen be reacted with sufficient monounsaturated carboxylic reactant at100° to 250° C., usually about 180° to 235° C., for about 0.5 to 10,e.g., 3 to 8 hours, so the product obtained will contain the desirednumber of moles of the monounsaturated carboxylic reactant per mole ofthe halogenated polymer. Processes of this general type are taught inU.S. Pat. Nos. 3,087,436; 3,172,892; 3,272,746 and others.Alternatively, the polymer and the monounsaturated carboxylic reactantare mixed and heated while adding chlorine to the hot material.Processes of this type are disclosed in U.S. Pat. Nos. 3,215,707;3,231,587; 3,912,764; 4,110,349; 4,234,435; and in U.K. 1,440,219.

While chlorination normally helps increase the reactivity of polyolefinswith monounsaturated carboxylic reactant, it is not necessary with thepresent polymers due to their high terminal bond content and reactivity.Also, the diene interpolymers may have additional unsaturation forfunctionalization. Preferably, therefore, the polymer and themono-unsaturated carboxylic reactant are contacted at elevatedtemperature to cause a thermal "ene" reaction to take place. Thermal"ene" reactions have been heretofore described in U.S. Pat. Nos.3,361,673 and 3,401,118, the disclosures of which are herebyincorporated by reference in their entirety. It has been surprisinglyfound that the terminally ethylenically-unsaturated ethylenealpha-olefin polymers used in this invention readily undergo suchthermal "ene" reactions under conditions in which the formation ofsediment, or other by-products contributing to product haze, is greatlyminimized or avoided altogether. The improved low sediment ene reactionproduct mixture is preferably formed using a polymer (more preferably,ethylene-propylene copolymers) having a number average molecular weightof from about 300 to 20,000 (e.g., from 700 to 20,000), more preferablyfrom about 900 to 15,000, still more preferably from about 1500 to10,000 (e.g., from about 1500 to 5,000), and most preferably greaterthan about 1800 to about 5,000. and a polydispersity of less than about4, preferably less than about 3, e.g., from 1.1 to 3.5, most preferablyfrom 1.2 to 3.

Preferably, the polymers used in this invention contain less than 5 wt%, more preferably less than 2 wt %, and most preferably less than 1 wt% of a polymer fraction comprising polymer molecules having a molecularweight of less than about 300, as determined by high temperature gelpremeation chromatography employing the corresponding polymercalibration curve. Such preferred polymers have been found to permit thepreparation of ene reaction products, particularly when employing maleicanhydride as the unsaturated acid reactant, with substantially novisibly observable sediment. In the event the polymer produced asdescribed above contains greater than about 5 wt % of such a lowmolecular weight polymer fraction, the polymer can be first treated byconventional means to remove the low molecular weight fraction to thedesired level prior to initiating the ene reaction, and preferably priorto contacting the polymer with the selected unsaturated carboxylicreactant(s). For example, the polymer can be heated preferably withinert gas (e.g., nitrogen) stripping, at elevated temperature under areduced pressure to volatilize the low molecular weight polymercomponents which can then be removed from the heat treatment vessel. Theprecise temperature, pressure and time for such heat treatment can varywidely depending on such factors as as the polymer number averagemolecular weight, the amount of the low molecular weight fraction to beremoved, the particular monomers employed and other factors. Generally,a temperature of from about 60° to 100° C. and a pressure of from about0.1 to 0.9 atmospheres and a time of from about 0.5 to 20 hours (e.g., 2to 8 hours) will be sufficient.

In this process, the selected polymer and monounsaturated carboxylicreactant are contacted for a time and under conditions effective to formthe desired ethylene alpha-olefin polymer substituted mono- ordicarboxylic acid material. Generally, the polymer and monounsaturatedcarboxylic reactant will be contacted in a polymer to unsaturatedcarboxylic reactant mole ratio usually from about 1:1 to 1:10, andpreferably from about 1:1 to 1:5, at an elevated temperature, generallyfrom about 120° to 260° C., preferably from about 160° to 240° C. Thereaction will be generally carried out, with stirring for a time of fromabout 1 to 20 hours, preferably from about 2 to 6 hours. The reaction ispreferably conducted in the substantial absence of O₂ and water (toavoid competing side reactions), and to this end can be conducted in anatmosphere of dry N₂ gas or other gas inert under the reactionconditions. The reactants can be charged separately or together as amixture to the reaction zone, and the reaction can be carried outcontinuously, semi-continuously or batchwise. Although not generallynecessary, the reaction can be carried out in the presence of a liquiddiluent or solvent, e.g., a hydrocarbon diluent such as minerallubricating oil, toluene, xylene, dichlorobenzene and the like. Thepolymer substituted mono- or dicarboxylic acid material thus formed canbe recovered from the liquid reaction mixture, e.g., after stripping thereaction mixture, if desired, with an inert gas such as N₂ to removeunreacted unsaturated carboxylic reactant.

The "ene" reaction product mixture thereby obtained has beensurprisingly found to have a substantially reduced content of sedimentor other solid by-products as impurities and can be employed, withoutfiltering, centrifuging, clarification, phase separation or otherconventional product purification treatments, as, e.g., an additive tolubricating oils or as intermediate in the preparation of derivativeproducts for use in lubricating oils, as will be more completelydescribed hereinafter.

The ene reaction product mixture is further improved by beingsubstantially free of chlorine, that is, by having a chlorine content ofless than about 25 ppm by weight, preferably less than about 10 ppm byweight.

The ene reaction product mixture comprising the desiredethylene-alpha-olefin substituted mono- or dicarboxylic acid material(e.g., ethylene-propylene polymer-substituted succinic anhydride) formedby the process of this invention will generally contain unreactedpolymer, (that is, polymer which is unsubstituted by the mono- ordicarboxylic acid moiety), in a concentration of less than about 40 wt.% (e.g., from 5 to 35 wt. %), more preferably less than about 30 wt. %(e.g from 10 to 25 wt. %) and will be generally characterized by a VRvalue ("viscosity ratio" value) of not greater than about 4.1, usuallynot greater than about 4.0, preferably from about 2.0 to 3.9, and mostpreferably from about 3.0 to 3.8. As used herein, the term "VR value" isintended to mean quotient determined by the expression (IV): ##EQU1##wherein VISa is the kinematic viscosity (KV) of the ene reaction productmixture at 100° C. in units of centistokes (as determined by ASTM MethodNo. D445) and VISb is the cold cranking simulator (CCS) viscosity of theene reaction product mixture at -20° C. in units of poise (as determinedby ASTM Method No. D2602), wherein the measurements are made upon a 2 wt% solution of the ene reaction product mixture in an oil (herein termedthe "reference oil") comprising S150N (solvent 150 neutral) minerallubricating oil (Exxon Company U.S.A.), wherein the such reference oilis characterized by an ASTM D445 kinematic viscosity of 5.2 cSt (100°C.) and an ASTM D2602 CCS viscosity of 19.2 poise (±0.4 poise) (at -20.oslashed.C). The "VR_(r) " value of the reference oil will then be about3.7±0.1.

Illustrative, therefore, of the improved ene reaction products of thisinvention are the following ethylene-propylene copolymer-substitutedsuccinic acids and succinic anhydrides (EPSA), ethylene-butene-1copolymer-substituted succinic acids and succinic anhydrides (EBSA)summarized in Table A below:

                  TABLE A                                                         ______________________________________                                                         Residual  Wt.   SA:Polymer                                                                            VR                                   Ene   Polymer    Halide    % ai  Mole Ratio                                                                            Value                                Product                                                                             (Mn)       (wppm)    (1)   (2)     (3)                                  ______________________________________                                        EPSA  300-20,000 ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EPSA  300-10,000 ≦10                                                                              ≧60                                                                          ≧1.0:1                                                                         ≦4.0                          EPSA  700-5,000  ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EPSA  700-5,000  ≦10                                                                              ≧60                                                                          ≧1.0:1                                                                         ≦4.0                          EPSA  5,500-20,000                                                                             ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EPSA  5,500-10,000                                                                             ≦10                                                                              ≧70                                                                          ≧0.7:1                                                                         ≦4.0                          EPSA  1,500-10,000                                                                             ≦10                                                                              70-90 ≧1.0:1                                                                         ≦4.1                          EBSA  300-20,000 ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EBSA  300-10,000 ≦10                                                                              ≧60                                                                          ≧1.0:1                                                                         ≦4.0                          EBSA  700-5,000  ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EBSA  700-5,000  ≦10                                                                              ≧60                                                                          ≧1.0:1                                                                         ≦4.0                          EBSA  5,500-20,000                                                                             ≦25                                                                              ≧60                                                                          ≧0.7:1                                                                         ≦4.1                          EBSA  5,500-10,000                                                                             ≦10                                                                              ≧70                                                                          ≧0.7:1                                                                         ≦4.0                          EBSA  1,500-10,000                                                                             ≦25                                                                              70-90 ≧1.0:1                                                                         ≦4.0                          ______________________________________                                         NOTES:                                                                        (1) Wt. % active ingredient.                                                  (2) SA = succinic anhydride; polymer = ethylenepropylene (EP) or ethylene     butylene (EB) copolymer; moles of polymer in ratio based on the total of      both the reacted and unreacted polymer; moles of "SA" based on the number     of moles of succinic anhydride moieties per mole of ene reaction product.

It will be understood that the ethylene alpha-olefin polymers (includingdiene interpolymers) of this invention which are charged to the reactionzone can be charged alone or together with (e.g., in admixture with)other polyalkenes derived from alkenes having from 1 to 20 carbon atoms(butene, pentene, octene, decene, dodecene, tetradodecene and the like)and homopolymers of C₃ to C₁₀, e.g., C₂ to C₅, monoolefins, andcopolymers of C₂ to C₁₀, e.g., C₂ to C₅, monoolefins, said additionalpolymer having a number average molecular weight of at least about 900,and a molecular weight distribution of less than about 4.0, preferablyless than about 3.0 (e.g, from 1.2 to 2.8). Preferred such additionalolefin polymers comprise a major molar amount of C₂ to C₁₀, e.g. C₂ toC₅ monoolefin. Such olefins include ethylene, propylene, butylene,isobutylene, pentene, octene-1, styrene, etc. Exemplary of theadditionally charged homopolymers is polypropylene, polyisobutylene, andpoly-n-butene the like as well as interpolymers of two or more of sucholefins such as copolymers of: ethylene and propylene (prepared byconventional methods other than as described above for the preferredethylene alpha-olefin copolymers employed in this invention, that is,ethylene-propylene copolymers which are substantially saturated, whereinless than about 10 wt % of the polymer chains contain ethylenicunsaturation); butylene and isobutylene; propylene and isobutylene; etc.Other copolymers include those in which a minor molar amount of thecopolymer monomers, e.g., 1 to 10 mole %, is a C₄ to C₁₈ non-conjugateddiolefin, e.g., a copolymer of isobutylene and butadiene: or a copolymerof ethylene, propylene and 1,4-hexadiene; etc. The additional sucholefin polymers charged to the reaction will usually have number averagemolecular weights of at least about 900, more generally within the rangeof about 1200 and about 5,000, more usually between about 1500 and about4,000. Particularly useful such additional olefin polymers have numberaverage molecular weights within the range of about 1500 and about 3,000with approximately one double bond per chain. An especially usefuladditional such polymer is polyisobutylene. Preferred are mixtures ofsuch polyisobutylene with ethylene-propylene copolymers wherein at least30 wt % of the copolymer chains contain terminal ethenylidenemonounsaturation as described above.

The number average molecular weight for such polymers can be determinedby several known techniques. A convenient method for such determinationis by gel permeation chromatography (GPC) which additionally providesmolecular weight distribution information, see W. W. Yau, J. J. Kirklandand D. D. Bly, "Modern Size Exclusion Liquid Chromatography", John Wileyand Sons, New York, 1979.

PREPARATION OF NUCLEOPHILICALLY-SUBSTITUTED DERIVATIVE PRODUCTS

The polymer substituted carboxylic acids/anhydrides/esters of thisinvention, prepared as described above, can be contacted with anucleophilic reactant, e.g., amines, alcohols, including polyols,amino-alcohols, reactive metal compounds, etc. to form the noveldispersants of this invention.

Amine compounds useful as nucleophilic reactants for reaction with thepolymer substituted mono- or dicarboxylic acid materials include mono-and (preferably) polyamines, of about 2 to 60, preferably 2 to 40 (e.g.3 to 20), total carbon atoms and about 1 to 12, preferably 3 to 12, andmost preferably 3 to 9 nitrogen atoms in the molecule. These amines maybe hydrocarbyl amines or may be hydrocarbyl amines including othergroups, e.g, hydroxy groups, alkoxy groups, amide groups, nitrites,imidazoline groups, and the like. Hydroxy amines with 1 to 6 hydroxygroups, preferably 1 to 3 hydroxy groups are particularly useful.Preferred amines are aliphatic saturated amines, including those of thegeneral formula: ##STR2## wherein R, R', R" and R'" are independentlyselected from the group consisting of hydrogen; C₁ to C₂₅ straight orbranched chain alkyl radicals; C₁ to C₂₅ straight or branched chainalkyl radicals; C₁ to C₁₂ alkoxy C₂ to C₆ alkylene radicals; C₂ to C₁₂hydroxy amino alkylene radicals; and C₁ to C₁₂ alkylamino C₂ to C₆alkylene radicals; and wherein R'" can additionally comprise a moiety ofthe formula: ##STR3## wherein R' is as defined above, and wherein r andr' can be the same or a different number of from 2 to 6, preferably 2 to4; and t and t' can be the same or different and are numbers of from 0to 10, preferably 2 to 7, and most preferably about 3 to 7, with theproviso that the sum of t and t' is not greater than 15. To assure afacile reaction, it is preferred that R, R', R", R'", r, r', t and t' beselected in a manner sufficient to provide the compounds of Formulas Vaand Vb with typically at least one primary or secondary amine group,preferably at least two primary or secondary amine groups. This can beachieved by selecting at least one of said R, R', R" or R'" groups to behydrogen or by letting t in Formula Vb be at least one when R'" is H orwhen the Vi moiety possesses a secondary amino group. The most preferredamine of the above formulas are represented by Formula Vb and contain atleast two primary amine groups and at least one, and preferably at leastthree, secondary amine groups.

Non-limiting examples of suitable amine compounds include:1,2-diaminoethane; 1,3-diaminopropane; 1,4diaminobutane;1,6-diaminohexane; polyethylene amines such as diethylene triamine;triethylene tetramine; tetraethylene pentamine; polypropylene aminessuch as 1,2-propylene diamine; d-(1,2-propylene)triamine;di-(1,3-propylene) triamine; N, N-dimethyl-1,3-di-aminopropane;N,N-di-(2-aminoethyl) ethylene diamine; N,N-di(2-hydroxyethyl)-1,3-propylene diamine; 3-dodecyloxypropylamine;N-dodecyl-1,3-propane diamine; tris hydroxymethylaminomethane (THAM);diisopropanol amine; diethanol amine; triethanol amine; mono-, di-, andtri-tallow amines; amino morpholines such asN-(3-amino-propyl)morpholine; and mixtures thereof.

Other useful amine compounds include: alicyclic diamines such as1,4-di(aminomethyl) cyclohexane, and heterocyclic nitrogen compoundssuch as imidazolines, and N-aminoalkyl piperazines of the generalformula (VII): ##STR4## wherein p₁ and p₂ are the same or different andare each integers of from 1 to 4, and n₁, n₂ and n₃ are the same ordifferent and are each integers of from 1 to 3. Non-limiting examples ofsuch amines include 2-pentadecyl imidazoline; N-(2-aminoethyl)piperazine; etc.

Commercial mixtures of amine compounds may advantageously be used. Forexample, one process for preparing alkylene amines involves the reactionof an alkylene dihalide (such as ethylene dichloride or propylenedichloride) with ammonia, which results in a complex mixture of alkleneamines wherein pairs of nitrogens are joined by alkylene groups, formingsuch compounds as diethylene triamine, triethylenetetramine,tetraethylene pentamine and isomeric piperazines. Low costpoly(ethyleneamines) compounds averaging about 5 to 7 nitrogen atoms permolecule are available commercially under trade names such as "PolyamineH", "Polyamine 400", "Dow Polyamine E-100", etc.

Useful amines also include polyoxyalkylene polyamines such as those ofthe formula (VIII):

    NH.sub.2 --alkylene--(--o-alkylene--).sub.m --NH.sub.2

where m has a value of about 3 to 70 and preferably 10 to 35; and theformula (IX):

    R.sup.4 --alkylene--(--o-alkylene--).sub.n'" --NH.sub.2.sbsb.a

where n'" has a value of about 1 to 40 with the provision that the sumof all the n'" values is from about 3 to about 70 and preferably fromabout 6 to about 35, and R⁴ is a polyvalent saturated hydrocarbonradical of up to ten carbon atoms wherein the number of substituents onthe R⁴ group is represented by the value of "a", which is a number offrom 3 to 6. The alkylene groups in either formula (VII) or (IX) may bestraight or branched chains containing about 2 to 7, and preferablyabout 2 to 4 carbon atoms.

The polyoxyalkylene polyamines of formulas (VII) or (IX) above,preferably polyoxyalkylene diamines and polyoxyalkylene triamines, mayhave average molecular weights ranging from about 200 to about 4000 andpreferably from about 400 to about 2000. The preferred polyoxyalkylenepolyoxyalkylene polyamines include the polyoxyethylene andpolyoxypropylene diamines and the polyoxypropylene triamines havingaverage molecular weights ranging from about 200 to 2000. Thepolyoxyalkylene polyamines are commercially available and may beobtained, for example, from the Jefferson Chemical Company, Inc. underthe trade name "Jeffamines D-230, D400, D-1000, D-2000, T403", etc.

A particularly useful class of amines are the polyamido and relatedamines disclosed in U.S. Pat. No. 4,857,217 (the disclosure of which ishereby incorporated by reference in its entirety), which comprisereaction products of a polyamine and an alpha, beta unsaturated compoundof the formula: ##STR5## wherein X is sulfur or oxygen, Y is --OR⁸,--SR⁸, or --NR⁸ (R⁹), and R⁵, R⁶, R⁷, R⁸ and R⁹ are the same ordifferent and are hydrogen or substituted or unsubstituted hydrocarbyl.ANy polyamine, whether aliphatic, cycloaliphatic, aromatic,heterocyclic, etc., can be employed provided it is capable of addingacross the acrylic double bond and amidifying with for example thecarbonyl group (--C(O)--) of the acrylate-type compound of formula X, orwith the thiocarbonyl group (--C(S)--) of the thioacrylate-type compoundof formula X.

When R⁵, R⁶, R⁷, R⁸ or R⁹ in Formula X are hydrocarbyl, these groups cancomprise alkyl, cycloalkyl, aryl, alkaryl, aralkyl orheterocyclic, whichcan be substituted with groups which are substantially inert to anycomponent of the reaction mixture under conditions selected forpreparation of the amido-amine. Such substituent groups include hydroxy,halide (e.g., Cl, F1, I, Br), --SH and alkylthio. When one or more of R⁵through R⁹ are alkyl, such alkyl groups can be straight or branchedchain, and will generally contain from 1 to 20, more usually from 1 to10, and preferably from 1 to 4, carbon atoms. Illustrative of such alkylgroups are methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl,nonyl, decyl, dodecyl, tridecyl, hexadecyl, octadecyl and the like. Whenone or more of R⁵ through R⁹ are aryl, the aryl group will generallycontain from 6 to 10 carbon atoms (e.g., phenyl, naphthyl).

When one or more of R⁵ through R⁹ are alkaryl, the alkaryl group willgenerally contain from about 7 to 20 carbon atoms, and preferably from 7to 12 carbon atoms. Illustrative of such alkaryl groups are tolyl,m-ethylphenyl, o-ethyltolyl, and m-hexyltolyl. When one or more of R⁵through R⁹ are aralkyl, the aryl component generally consists of phenylor (C₁ to C₆) alkyl-substituted phenol and the alkyl component generallycontains from 1 to 12 carbon atoms, and preferably from 1 to 6 carbonatoms. Examples of such aralkyl groups are benzyl, o-ethylbenzyl, and4-isobutylbenzyl. When one or more of R⁵ and R⁹ are cycloalkyl, thecycloalkyl group will generally contain from 3 to 12 carbon atoms, andpreferably from 3 to 6 carbon atoms. Illustrative of such cycloalkylgroups are cyclopropyl, cyclobutyl, cyclohexyl, cyclooctyl, andcyclododecyl. When one or more of R⁵ through R⁹ are heterocyclic, theheterocyclic group generally consists of a a compound having at leastone ring of 6 to 12 members in which one or more ring carbon atoms isreplaced by oxygen or nitrogen. Examples of such heterocyclic groups arefuryl, pyranyl, pyridyl, piperidyl, dioxanyl, tetrahydrofuryl, pyrazinyland 1,4-oxazinyl.

The alpha, beta ethylenically unsaturated carboxylate compounds employedherein have the following formula: ##STR6## Wherein R⁵, R⁶ R⁷, and R⁸are the same or different and are hydrogen or substituted orunsubstituted hydrocarbyl as defined above. Examples of such alpha,beta-ethylenically unsaturated carboxylate compounds of formula XI areacrylic acid, methacrylic acid, the methyl, ethyl, isopropyl, n-butyland isobutyl esters of acrylic and methacrylic acids, 2-butenoic acid,2-hexenoic acid, 2-decenoic acid, 3-methyl-2-heptenoic acid,3-methyl-2-butenoic acid, 3-phenyl-2-propenoic acid,3-cyclohexyl-2-butenoic acid, 2-methyl-2-butenoic acid,2-ppropyl-2-propenoic acid, 2-isopropyl-2-hexenoic acid,2,3-dimethyl-2butenoic acid, 3-cyclohexyl-2-methyl-2-pentenoic acid,2-propenoic acid, methyl 2-propenoate, methyl 2-methyl 2-propenoate,methyl 2-butenoate,ethyl 2-hexnoate, isopropyl 2-decenoate, phenyl2-pentenoate, tertiary butyl 2-propenoate, octadecyl 2-propenoate,dodecyl 2-decanoate, cyclopropyl 2,3-dimethyl-2-butenoate, methyl3-phenyl-2-propenoate, and the like.

The alpha, beta ethylenically unsaturated carboxylate thioester compoundemployed herein have the following formula: ##STR7## Wherein R⁵, R⁶, R⁷,and R⁸ are the same or different and are hydrogen or substituted orunsubstituted hydrocarbyl as defined above. Examples of such alpha,beta-ethylenically unsaturated carboxylate thioesters of formula XII aremethylmercapto 2-butenoate, ethylmercapto 2-hexenoate, isopropylmercapto2decanoate, phenylmercapto 2-pentenoate, tertiary butylmercapto2-propenoate, octadecylmercapto 2-propenoate, dodecylmercapto2-decenoate, cyclopropylmercapto 2,3-dimethyl-2-butenoate,methylmercapto 3-phenyl-2-propenoate, methylmercapto 2-propenoate,methylmercapto 2-methyl-2-propenoate, and the like.

The alpha, beta ethylenically unsaturated carboxyamide compoundsemployed herein have the following formula: ##STR8## Wherein R⁵, R⁶, R⁷,R⁸ and R⁹ are the same or different and are hydrogen or substituted orunsubstituted hydrocarbyl as defined above. Examples of alpha,beta-ethylenically unsaturated carboxyamides of formula XIII are2-butenamide, 2-hexenamide, 2-decenamide, 3-methyl-2-heptenamide,3-methyl-2-butenamide, 3-phenyl-2-propenamide,3-cyclohexyl-2-butenamide, 2-methyl-2-butenamide,2-propyl-2-propenamide, 2-isopropyl-2-hexenamide,2,3dimethyl-2-butenamide, 3cyclohexyl-2-methyl-2-pentenamide, N-methyl2-butenamide, N-methyl 2-butenamide, N,N-diethyl 2-hexenamide,N-isopropyl 2-decenamide, N-phenyl 2-pentenamide, N-tertiary butyl2-propenamide, N-octadecyl 2-propenamide, N-N-didodecyl 2-decenamide,N-cyclopropyl 2,3-dimethyl-2-butenamide, N-methyl3-phenyl-2-propenamide, 2-propenamide, 2-methyl-2-propenamide,2ethyl-2-propenamide and the like.

The alpha, beta ethylenically unsaturated thiocarboxylate compoundsemployed herein have the following formula: ##STR9## Wherein R⁵, R⁶, R⁷,R⁸ and R⁹ are the same or different and are hydrogen or substituted orunsubstituted hydrocarbyl as defined above. Examples of alpha,beta-ethylenically unsaturated thiocarboxylate compounds of formula XIVare 2-butenthioic acid, 2-hexenthioic acid, 2decenthioic acid,3-methyl-2-heptenthioic acid, 3-methyl-2-butenthioic acid,3-phenyl-2-propenthioic acid, 3-cyclohexyl-2-butenthioic acid,2-methyl-2-butenthioic acid, 2-propyl-2-propenthioic acid,2-isopropyl-2-hexenthioic acid, 2,3-dimethyl-2-butenthioic acid,3-cyclohexyl-2-methyl-2-pententhioic acid, 2-propenthioic acid, methyl2-propenthioate methyl 2-methyl 2-propenthioate, methyl 2-butenthioate,ethyl 2-hexenthioate, isopropyl 2-decenthioate, phenyl 2-pententhioate,tertiary butyl 2-propenthioate, octadecyl 2-propenthioate, dodecyl2-decenthioate, cyclopropyl 2,3-dimethyl-2-butenthioate, methyl3-phenyl-2-propenthioate, and the like.

The alpha, beta ethylenically unsaturated dithioic acid and acid estercompounds employed herein have the following formula: ##STR10## WhereinR⁵, R⁶, R⁷, and R⁸ are the same or different and are hydrogen orsubstituted or unsubstituted hydrocarbyl as defined above. Examples ofalpha, beta-ethylenically unsaturated dithioic acids and acid esters offormula XV are 2-butendithioic acid, 2-hexendithioic acid,2-decendithioic acid, 3-methyl-2-heptendithioic acid,3-methyl-2-butendithioic acid, 3-phenyl-2-propendithioic acid,3-cyclohexyl-2-butendithioic acid, 2-methyl-2-butendithioic acid,2-propyl-2-propendithioic acid, 2-isopropyl-2-hexendithioic acid,2,3dimethyl-2-butendithioic acid, 3cyclo-hexyl-2-methyl-2-pentendithioicacid, 2-propendithioic acid, methyl 2-methyl 2-propendithioate, methyl2-butendithioate, ethyl 2-hexendithioate, isopropyl 2-decendithioate,phenyl 2-pentendithioate, tertiary butyl 2-propendithioate, octadecyl2-propendithioate, dodecyl 2-decendithioate, cyclopropyl2,3-dimethyl-2-butendithioate, methyl 3-phenyl-2-propendithioate, andthe like.

The alpha, beta ethylenically unsaturated thiocarboxyamide compoundsemployed herein have the following formula: ##STR11## Wherein R⁵, R⁶,R⁷, R⁸ and R⁹ are the same or different and are hydrogen or substitutedor unsubstituted hydrocarbyl as defined above. Examples of alpha,beta-ethylenically unsaturated thiocarboxyamides of formula XVI are2-butenthioamide, 2-hexenthioamide, 2-decenthioamide,3-methyl-2-heptenthioamide, 3-methyl-2-butenthioamide,3-phenyl-2-propenthioamide, 3-cyclohexyl-2-butenthioamide,2-methyl-2-butenthioamide, 2-propyl-2-propen-thioamide,2-isopropyl-2-hexenthioamide, 2,3-dimethyl-2-butenthioamide,3-cyclohexyl-2-methyl-2-pententhioamide, N-methyl 2-butenthioamide,N,N-diethyl 2-hexenthioamide, N-isopropyl 2-decenthioamide, N-phenyl2-pententhioamide, N-tertiary butyl 2-propenthioamide, N-octadecyl2-propenthioamide, N-N-didodecyl 2-decenthioamide, N-cyclopropyl2,3-dimethyl-2-butenthioamide, N-methyl 3-phenyl-2-propenthioamide,2-propen-thioamide, 2-methyl-2-propenthioamide,2-ethyl-2-propenthioamide and the like.

Preferred compounds for reaction with the polyamines in accordance withthis invention are lower alkyl esters of acrylic and (lower alkyl)substituted acrylic acid. Illustrative of such preferred compounds arecompounds of the formula: ##STR12## where R⁷ is hydrogen or a C₁ to C₄alkyl group, such as methyl, and R⁸ is hydrogen or a C₁ to C₄ alkylgroup, capable of being removed so as to form an amido group, forexample, methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl,aryl, hexyl, etc. In the preferred embodiments these compounds areacrylic and methacrylic esters such as methyl or ethyl acrylate, methylor ethyl methacrylate. When the selected alpha, beta-unsaturatedcompound comprises a compound of formula X wherein X' is oxygen, theresulting reaction product with the polyamine contains at least oneamido linkage (--C(O)N<) and such materials are herein termed"amido-amines." Similarly, when the selected alpha, beta unsaturatedcompound of formula X comprises a compound wherein X' is sulfur, theresulting raction product with the polyamine contains thioamide linkage(--C(S)N<) and these materials are herein termed "thioamido-amines." Forlo convenience, the following discussion is directed to the preparationand use of amido-amines, although it will be understood that suchdiscussion is also applicable to the thioamido-amines.

The type of amido-amine formed varies with reaction conditions. Forexample, a more linear amido-amine is formed where substantiallyequimolar amounts of the unsaturated carboxylate and polyamine arereacted. The presence of excesses of the ethylenically unsaturatedreactant of formula X tends to yield an amido-amine which is morecross-linked than that obtained where substantially equimolar amounts ofreactants are employed. Where for economic or other reasons across-linked amido-amine using excess amine is desired, generally amolar excess of the ethylenically unsaturated reactant of about at least10%, such as 10-300%, or greater, for example, 25-200%, is employed.

For more efficient cross-linking an excess of carboxylated materialshould preferably be used since a cleaner reaction ensures. For example,a molar excess of about 10-100% or greater such as 10-50%, butpreferably an excess of 30-50%, of the carboxylated material. Largerexcess can be employed, if desired.

In summary, without considering other factors, equimolar amounts ofreactants tend to produce a more linear amido-amine whereas excess ofthe formula XII reactant tends to yield a more cross-linked amido-amine.It should be noted that the higher the polyamine (i.e., in greater thenumber of amino groups on the molecule) the greater the statisticalprobability of cross-linking since, for example, atetraalkylenepentamine, such as tetraethylene pentamine has more labilehydrogens than ethylene diamine.

These amido-amine adducts so formed are characterized by both amido andamino groups. In their simplest embodiments they may be represented byunits of the following idealized formula (XVIII): ##STR13## wherein theR¹⁰ 's, which may be the same or different, are hydrogen or asubstituted group, such as a hydrocarbon group, for example, alkyl,alkenyl, alkynyl, aryl, etc., and A is a moiety of the polyamine which,for example, may be aryl, cycloalkyl, alkyl, etc., and n₄ is an integersuch as 1-10 or greater.

The above simplified formula represents a linear amido-amine polymer.However, cross-linked polymers may also be formed by employing certainconditions since the polymer has labile hydrogens which can furtherreact with either the unsaturated moiety by adding across the doublebond or by amidifying with a carboxylate group.

Preferably, however, the amido-amines employed in this invention are notcross-linked to any substantial degree, and more preferably aresubstantially linear.

Preferably, the polyamine reactant contains at least one primary amine(and more preferably from 2 to 4 primary amines) group per molecule, andthe polyamine and the unsaturated reactant of formula X are contacted inan amount of from about 1 to 10, more preferably from about 2 to 6, andmost preferably from about 3 to 5, equivalents of primary amine in thepolyamine reactant per mole of the unsaturated reactant of formula X.

The reaction between the selected polyamine and acrylate-type compoundis carried out at any suitable temperature. Temperatures up to thedecomposition points of reactants and products can be employed. Inpractice, one generally carried out the reaction by heating thereactants below 100° C., such as 80°-90° C., for a suitable period oftime, such as a few hours. Where an acrylic-type ester is employed, theprogress of the reaction can be judged by the removal of the alcohol informing the amide. During the early part of the reaction alcohol isremoved quite readily below 100° C. in the case of low boiling alcoholssuch as methanol or ethanol. As the reaction slows, the temperature israised to push the polymerization to completion and the temperature maybe raised to 150° C. toward the end of the raction. Removal of alcoholis a cnvenient method of judging the progress and completion of thereaction which is generally continued until no more alcohol is evolved.Based on removal of alcohol, the yields are generally stoichiometric. Inmore difficult reactions, yields of at least 95% are generally obtained.

Similarly, it will be understood that the reaction of an ethylenicallyunsaturated carboxylate thioester of formula XII liberates thecorresponding HSR⁸ compound (e.g., H₂ S when R⁸ is hydrogen) as aby-product, and the reaction of an ethylenically unsaturatedcarboxyamide of formula XIII liberates the corresponding HNR⁸ (R⁹)compound (e.g., ammonia when R⁸ and R are each hydrogen) as by-product.

The reaction time involved can vary widely depending on a wide varietyof factors. For example, there is a relationship between time andtemperature. In general, lower temperature demands longer times.Usually, reaction times of from about 2 to 30 hours, such as 5 to 25hours, and preferably 3 to 10 hours will be employed.

Although one can employ a solvent, the reaction can be run without theuse of any solvent. In fact, where a high degree of cross-linking isdesired, it is preferable to avoid the use of a solvent and mostparticularly to avoid a polar solvent such as water. However, takinginto consideration the effect of solvent on the reaction, where desired,any suitable solvent can be employed, whether organic or inorganic,polar or non-polar.

As an example of the amido-amine adducts, the reactin of tetraethylenepentaamine (TEPA) with methyl methacrylate can be illustrated asfollows: ##STR14##

In a preferred embodiment, the nucleophilic reactant comprises abranched chain nitrogen containing adduct formed by a process whichcomprises: (a) contacting in a first liquid reaction mixture a firstnitrogen-containing compound having at least two reactive nitrogenmoieties with a polyfunctional reactant having within its structure afirst functional group reactive with a --NH-- group, and at least oneadditional functional group reactive with a --NH-- group, in an amountand under conditions sufficient to selectively react the firstfunctional groups in the polyfunctional ractant with the reactivenitrogen moieties to form a first reaction mixture containing a firstadduct; and (b) contacting the first adduct with a secondnitrogen-containing compound having at lest two --NH-- groups in anamount and under conditions sufficient to react the additionalfunctional groups in the first adduct with said --NH-- groups in thesecond nitrogen-containing compound per nitrogen-containing moietyderived from the first nitrogen-containing compound and (ii) at leasttwo unreacted primary or secondary amine groups per molecule.

Preferably, the branched chain nitrogen-containing adduct comprises abranched amido-amine adduct, and more preferably to a star branchedamido-amine adduct, formed by (a) reacting a first nitrogen-containingcompound (e.g., ammonia or an organic amine) with an alpha,beta-unsaturated compound of the formula: ##STR15## wherein W¹ is sulfuror oxygen, Y is --OR⁴, --SR⁴, or --NR⁴ (R⁵), and R¹, R², R³, R⁴ and R⁵are the same or different and are hydrogen or substituted orunsubstituted hydrocarbyl, to form a first adduct containing unreacted--C(W¹)--Y groups; and (b) reacting the first adduct with a polyamine(e.g., a polyalkylene polyamine) to form a second adduct containingunreacted --NH-- groups (preferably primary amine groups) and comprisinga branched amido-amine oligomer.

The first above adduct is prepared by contacting a polyfunctionalreactant with a first nitrogen-containing compound containing at leasttwo (e.g., from 2 to 20), preferably at least 3 (e.g., from 3 to 15),and most preferably from 3 to 8, reactive nitrogen moieties (that is,the total of the nitrogen-bonded H atoms) per molecule of the firstnitrogen-containing compound. The first nitrogen-containing compoundwill generally comprise at least one member selected from the groupconsisting of ammonia, organic primary monoamines and organic polyaminescontaining at least one primary amine group or at least two secondaryamine groups per molecule.

Most preferred as the first nitrogen-containing compound are membersselected from the group consisting of ammonia and organic diprimaryamines having from 2 to 12 carbon atoms and from 2 to 8 nitrogen atomsper molecule. Examples of such preferred organic diprimary amines areethylene diamine, propylene diamine, diethylene triamine, dipropylenetriamine, triethylene tetraamine, tripropylene tetraamine, tetraethylenepentaamine, tetrapropylene pentaamine, polyhexamethylene diamine, phenyldiamine.

The polyfunctional ractants useful in this invention include compoundshaving the formula (XX): ##STR16## wherein W¹ and W² are the same ordifferent and are O or S, X and Y are the same or different, andpreferably are each groups reactive with a --NH-- group (i.e., with NH₃or with primary or secondary amine groups), T is a substituted orunsubstituted hydrocarbon moiety, "a" is 0 or 1, "b" is 0 or 1, and "c"is an integer of at least 1, with the provisos that c=1 when a=0 and b=1when a=1, and with the further proviso that at least two of X, Y and Tare reactive with a --NH-- group.

The X and Y functional groups are the same or different and includegroups selected from the group consisting of: halide, --OR⁴, --SR⁴,--N(R⁴)(R⁵), --Z¹ C(O)OR⁴, --C(O)R⁴, --(R³)C═C(R¹)(R²), --Z¹ -nitrile,--Z¹ -cyano, --Z¹ -thiocyano, --Z¹ -isothiocyano, and --Z¹ -isocyano,wherein R¹, R², R³, R⁴ and R⁵ are the same or different and are H orsubstituted or unsubstituted hydrocarbyl and wherein Z¹ is C₁ to C₂₀(preferably C¹ to C¹⁰) bivalent hydrocarbylene (preferably alkylene orarylene). If a=b=1, and T contains at least one >C═C< group, X and Y cantogether further comprise --O-- or --S--, to provide as reactants aclass of ethylenically unsaturated and aromatic anhydrides andsulfo-anhydrides. Preferably, the X and Y groups in the selectedpolyfunctional reactant are different, and the reactivity of the Xmoiety with --NH-- groups, under the selected reaction conditions, isgreater than the reactivity of the Y moieties with such --NH-- groups topermit a substantially selective reaction of the X groups with the firstnitrogen-containing compound as described below. The relative reactivityof these groups on a polyfunctional reactant can be readily determinedby conventional methods.

When R¹, R², R³, R⁴, or R⁵ are hydrocarbyl, these groups can comprisealkyl, cycloalkyl, aryl, aralkyl or heterocyclic, which can besubstituted with groups which are substantially inert to any componentof the reaction mixture under conditions selected for preparation of theamido-amine. Such substituent groups include hydroxy, halide (e.g., C1,F1, I, Br), --SH and alkylthio. When one or more of R¹ through R⁵ arealkyl, such alkyl groups can be straight or branched chain, and willgenerally contain from 1 to 20, more usually from 1 to 10, andpreferably from 1 to 4, carbon atoms. Illustrative of such alkyl groupsare methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl,decyl, dodecyl, tridecyl,hexadecyl, octadecyl and the like. When one ormore of R¹ through R⁵ are aryl, the aryl group will generally containfrom 6 to 10 carbon atoms (e.g., phenyl, nephthyl).

When one or more of R¹ through R⁵ are alkaryl, the alkaryl group willgenerally contain from about 7 to 20 carbon atoms, and preferably from 7to 12 carbon atoms. Illustrative of such alkaryl groups are tolyl,m-ethylphenyl, o-ethyltolyl, and m-hexyltolyl. When one or more of R¹through R⁵ are aralkyl, the aryl component generally consists of phenylor (C₁ to C₆) alkyl-substituted phenol and the alkylcomponent generallycontains from 1 to 12 carbon atoms, and preferably from 1 to 6 carbonatoms. Examples of such aralkyl groups are benzyl, o-ethylbenzyl, and4-isobutylbenzyl. When one or more of R¹ through R⁵ are cycloalkyl, thecycloalkyl group will generally contain from 3 to 12 carbon atoms, andpreferably from 3 to 6 carbon atoms. Illustrative of such cycloalkylgroups are cyclopropyl, cyclobutyl, cyclohexyl, cyclooctyl, andcyclododecyl. When one or more of R¹ through R⁵ are heterocyclic, theheterocyclic group generally consists fo a compound having at lest onering of 6 to 12 members in which one or more ring carbon atoms isreplaced by oxygen or nitrogen. Examples of such heterocyclic groups arefuryl, pyranyl, pyridyl, piperidyl, dioxanyl, tetrahydrofuryl, pyrazinyland 1,4-oxazinyl.

T is a polyvalent organic radical whose valence is equal to c+1, wherein"c" is an integer of at least 1, preferably 1 to 3. Ordinarily T willnot contain more than 20 carbon atoms and preferably not more than 10carbon atoms. T can therefore include divalent groups such as saturatedand unsaturated hydrocarbylene (e.g., alkylene, alkenylene, arylene, andthe like). When T is substituted, it can contain one or moresubstituents selected from the class consisting of halo, lower alkoxy,lower alkyl mercapto, nitro, lower alkyl, carboxy and oxo. It also maycontain interrupting groups such as --O--, --S--, --S(O)--, --S(O)₂ --,--NH--, --C(O)-- and the like.

Exemplary of Z¹ groups are C¹ to C¹⁰ branched and straight chainedalkylene such as --(CH₂)_(f) -- wherein "f" is an integer of from 1 to10 (e.g., --CH₂ --, --C₂ H₄ --, --C₃ H₇ --, --C₄ H₈ --, --C₅ H₁₀ --, andthe like), and C₆ to C₂₀ arylene, and alkyl-substituted arylene such as--Ar--, --Ar--((CH₂)_(f))--, --((CH₂)_(f))--Ar--, --Ar--((CH₂)_(f)--Ar-- and the like, wherein Ar is phenylene, methylphenylene,naphthylene, methylnaphthylene and the like and wherein f is as definedabove.

Examples of polyfunctional reactants of formula XX wherein X is(R¹)(R²)C═C(R³)--, a=b=0 and c=1 are difunctional reactants comprisingalpha, beta-ethylenically unsaturated compounds selected from the groupconsisting of compounds of the formula: ##STR17## wherein W¹ is sulfuror oxygen, Y is as defined above, and is preferably --OR⁴, --SR⁴, or--NR⁴ (R⁵), wherein R¹, R², R³, R⁴ and R⁵ are as defined above.

Preparation of the Dispersant

The amine is readily reacted with the selected material, e.g., theethylene-propylene copolymer substituted succinic anhydride, by reactingan oil solution containing 5 to 95 wt. % of the polymer substitutedmono- or dicarboxylic acid material at about 100° to 250° C., preferably125° to 175° C., generally for 1 to 10, e.g., 2 to 6 hours until thedesired amount of water is removed. The heating is preferably carriedout to favor formation of imides or mixtures of imides and amides,rather than amides and salts.

Reaction ratios of polymer substituted mono- and dicarboxylic acidmaterial to equivalents of amine as well as the other nucleophilicreactants described herein can vary considerably, depending on thereactants and type of bonds formed. When the polymer comprises a polymerlo substituted dicarboxylic acid material, containing dicarboxylic acidproducing moieties derived from any of the above monounsaturateddicarboxylic acids, or anhydride or ester derivatives thereof, generallyfrom 0.05 to 1.0, preferably from about 0.1 to 0.6, e.g., 0.2 to 0.4,moles of dicarboxylic acid moiety content (e.g., grafted maleicanhydride content) is used, per equivalent of nucleophilic reactant,e.g., amine. For example, about 0.8 mole of a pentamine (having twoprimary amino groups and 5 equivalents of nitrogen per molecule) ispreferably used to convert into a mixture of amides and imides, theproduct formed by reacting one mole of polymer with sufficient maleicanhydride to add 1.6 moles of succinic anhydride groups per mole ofpolymer, i.e., preferably the pentamine is used in an amount sufficientto provide about 0.4 mole (that is 1.6/ 0.8×5! mole) of succinicanhydride moiety per nitrogen equivalent of the amine. If anamido-amine, as above, is employed, generally from 1 to 5, preferablyfrom about 1.5 to 3 moles of dicarboxylic acid moiety content (e.g.,grafted maleic anhydride content) is used per equivalent of amido-aminereactant, e.g., amine.

When the polymer comprises a polymer substituted monocarboxylic acidmaterial, containing monocarboxylic acid producing moieties derived fromany of the above monounsaturated monocarboxylic acids, or esterderivatives thereof, generally from 0.05 to 1.0, preferably from about0.1 to 0.6, e.g., 0.2 to 0.4, moles of monocarboxylic acid moietycontent (e.g., grafted acrylic acid content) is used, per equivalent ofnucleophilic reactant, e.g., amine. If an amido-amine, as above, isemployed, generally from 1 to 5, preferably from about 1.5 to 3 moles ofmonocarboxylic acid moiety content (e.g., grafted acrylic acid content)is used per equivalent of amido-amine reactant, e.g., amine.

An example of the reaction of an amido-amine reactant with a polymermono- or dicarboxylic acid producing reactant is the reaction ofethylene-propylene copolymer substituted succinic anhydride (EPSA) witha polyamido-amine having two terminal --NH₂ groups, which can beillustrated as follows: ##STR18## where x and y are each integers offrom 0 to 10, EP represents an ethylene-propylene copolymer group asdescribed above, Z¹ and Z² are moieties of the formula: ##STR19##wherein R¹⁰, A and n₄ are as defined above for Formula XVIII. Preferredare amido-amine reactin products of the above equation wherein R¹⁰ is H,and most preferably wherein x and y are each zero, and A is --(CH₂)₂ --or --(CH₃ H₇)--.

It will be understood that the amine reactant can comprise one or amixture of any of the above described amines, such as a mixture of anamido-amine and a polyalkylene polyamine. substituted mono- ordicarboxylic acid producing material and amine will be contacted for atime and under conditions sufficient to react substantially ail of theprimary nitrogens in the amine reactant. The progress of this reactioncan be followed by infrared analysis.

The dispersant-forming reaction can be conducted in a polar or non-polarsolvent (e.g., xylene, toluene, benzene and the like), and is preferablyconducted in the presence of a mineral or synthetic lubricating oil.

Tris(hydroxymethyl) amino methane (THAM) can be reacted with theaforesaid polymer substituted acid material to form amides, imides orester type additives as taught by U.K. 984,409, or to form oxazolinecompounds and borated oxazoline compounds as described, for example, inU.S. Pat. Nos. 4,102,798; 4,116,876 and 4,113,639.

The ashless dispersants may also be esters derived from the aforesaidethylene alpha-olefin polymer substituted mono- or dicarboxylic acidmaterial and from hydroxy compounds such as monohydric and polyhydricalcohols or aromatic compounds such as phenols and naphthols, etc. Thepolyhydric alcohols are the most preferred hydroxy compound andpreferably contain from 2 to about 10 hydroxy radicals, for example,ethylene glycol, diethylene glycol, triethylene glycol, tetraethyleneglycol, dipropylene glycol, and other alkylene glycols in which thealkylene radical contains from 2 to about 8 carbon atoms. Other usefulpolyhydric alcohols include glycerol, mono-oleate of glycerol,monostearate of glycerol, monomethyl ether of glycerol, pentaerythritol,dipentaerythritol, and mixtures thereof.

The ester dispersant may also be derived from unsaturated alcohols suchas allyl alcohol, cinnamyl alcohol, propargyl alcohol,l-cyclohexane-3-ol, and oleyl alcohol. Still other classes of thealcohols capable of yielding the esters of this invention comprise theether-alcohols and amino-alcohols including, for example, theoxy-alkylene, oxy-arylene-, amino-alkylene-, andamino-arylene-substituted alcohols having one or more oxy-alkylene,amino-alkylene or amino-arylene oxy-arylene radicals. They areexemplified by Cellosolve, Carbitol, N,N,N',N'-tetrahydroxy-trimethylenedi-amine, and ether-alcohols having up to about 150 oxy-alkyleneradicals in which the alkylene radical contains from 1 to about 8 carbonatoms.

The ester dispersant may be di-esters of succinic acids or acidicesters, i.e., partially esterified succinic acids; as well as partiallyesterified polyhydric alcohols or phenols, i.e., esters having freealcohols or phenolic hydroxyl radicals. Mixtures of the aboveillustrated esters likewise are contemplated within the scope of thisinvention.

The ester dispersant may be prepared by one of several known methods asillustrated for example in U.S. Pat. No. 3,381,022. The ester dispersantmay also be borated, similar to the nitrogen containing dispersants, asdescribed above.

Hydroxyamines which can be reacted with the aforesaid ethylenealpha-olefin polymer substituted dicarboxylic acid material to formdispersants include 2-amino-1butanol, 2-amino-2-methyl-1-propanol,p-(beta-hydroxyethyl)-aniline, 2-amino-1-propanol, 3-amino-1-propanol,2-amino-2-methyl -1,3-propane-diol, 2-amino-2-ethyl-1,3-propanediol,N-(beta-hydroxypropyl)-N'-(beta-amino-ethyl)-piperazine,tris(hydroxymethyl) amino-methane (also known astrismethylolaminomethane), 2-amino-1-butanol, ethanolamine,beta-(beta-hydroxyethoxy)-ethylamine, and the like. Mixtures of these orsimilar amines can also be employed. The above description ofnucleophilic reactants suitable for reaction with the ethylenealpha-olefin polymer substituted dicarboxylic acid or anhydride includesamines, alcohols, and compounds of mixed amine and hydroxy containingreactive functional groups, i.e., amino-alcohols.

Reactive metals or reactive metal compounds useful for reaction with theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention are those which will form carboxylic acidmetal salts with the ethylene-alpha-olefin polymer substituted mono- anddicarboxylic acid materials of this invention and those which will formmetal-containing complexes with such dispersant derivative compositionsproduced by reacting the ethylene-alpha-olefin polymer substituted mono-and dicarboxylic acid materials with amines and/or alcohols as discussedabove. Reactive metal compounds useful for the formation of suchcomplexes are disclosed in U.S. Pat. No. 3,306,908. Complex-formingmetal reactants include the nitrates, nitrites, halides, carboxylates,phosphates, phosphites, sulfates, sulfites, carbonates, borates, andoxides of cadmium as well as metals having atomic numbers from 24 to 30(including chromium, manganese, iron, cobalt, nickel, copper and zinc).These metals are the so-called transition or co-ordination metals, i.e.,they are capable of forming complexes by means of their secondary orco-ordination valence. Specific examples of the complex-forming metalcompounds useful as the reactant in this invention are cobaltousnitrate, cobaltous oxide, cobaltic oxide, cobalt nitrite, cobalticphosphate, cobaltous chloride, cobaltic chloride, cobaltous carbonate,chromous acetate, chromic acetate, chromic bromide, chromous chloride,chromic fluoride, chromous oxide, chromium dioxide, chromic oxide,chromic sulfite, chromous sulfate heptahydrate, chromic sulfate, chromicformate, chromic hexanoate, chromium oxychloride, chromic phosphite,manganous acetate, manganous benzoate, manganous carbonate, manganesedichloride, manganese trichloride, manganous citrate, manganous formate,manganous nitrate, manganous oxalate, manganese monooxide, manganesedioxide, manganese trioxide, manganese heptoxide, manganic phosphate,manganous pyrophosphosate, manganic metaphosphate, manganoushypophosphite, manganous valerate, ferrous acetate, ferric benzoate,ferrous bromide, ferrous carbonate, ferric formate, ferrous lactate,ferrous nitrate, ferrous oxide, ferric oxide, ferric hypophosphite,ferric sulfate, ferrous sulfite, ferric hydrosulfite, nickel dibromide,nickel dichloride, nickel nitrate, nickel dioleate, nickel stearate,nickel sulfite, cupric propionate, cupric acetate, cupric metaborate,cupric benzoate, cupric formate, cupric laurate, cupric nitrite, cupricoxychloride, cupric palmitate, cupric salicylate, zinc benzoate, zincborate, zinc bromide, zinc chromate, zinc dichromate, zinc iodide, zinclactate, zinc nitrate, zinc oxide, zinc stearate, zinc sulfite, cadmiumbenzoate, cadmimum carbonate, cadmium butyrate, cadmium chloroactate,cadmium, fumerate, cadmium nitrate, cadmium di-hydrogenphosphate,cadmium sulfite, and cadmium oxide. Hydrates of the above compounds areespecially convenient for use in the process of this invention.

U.S. Pat. No. 3,306,908 is expressly incorporated herein by referencefor its discussion of reactive metal compounds suitable for forming suchcomplexes and its disclosure of processes for preparing the complexes.

Basically, those processes are applicable to the dispersant derivativecompositions of the ethylene-alpha-olefin polymer substituted mono- anddicarboxylic acid materials of this invention with the amines asdescribed above by substituting, or on an equivalent basis, theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention with the high molecular weight carboxylicacid acylating agents disclosed in U.S. Pat. No. 3,306,908. The ratio ofequivalents of the acylated amine thus produced and the complex-formingmetal reactant remains the same as disclosed in U.S. Pat. No. 3,306,908.

U.S. Pat. No. Reissue 26,433 discloses metals useful in preparing saltsfrom the dispersant derivative compositions of the ethylene-alpha-olefinpolymer substituted mono- and dicarboxylic acid materials of thisinvention and amines as described hereinabove. Metal salts are prepared,according to this patent, from alkali metals, alkaline earth metals,zinc, cadmium, lead, cobalt and nickel. Examples of a reactive metalcompound suitable for use herein are sodium oxide, sodium hydroxide,sodium carbonate, sodium methylate, sodium propylate, sodium pentylate,sodium phenoxide, potassium oxide, potasium hydroxide, potassiumcarbonate, potassium methylate, potassium pentylate, potassiumphenoxide, lithium oxide, lithium hydroxide, lithium carbonate, lithiumpentylate, calcium oxide, calcium hydroxide, calcium carbonate, calciummethylate, calcium ethylate, calcium propylate, calcium chloride,calcium fluoride, calcium pentylate, calcium phenoxide, calcium nitrate,barium oxide, barium hydroxide, barium carbonate, barium chloride,barium fluoride, barium methylate, barium propylate, barium pentylate,barium nitrate, magnesium oxide, magnesium hydroxide, magnesiumcarbonate, magnesium ethylate, magnesium propylate, magnesium chloride,magnesium bromide, barium, iodide, magnesium phenoxide, zinc oxide, zinchydroxide, zinc carbonate, zinc methylate, zinc propylate, zincpentylate, zinc chloride, zinc fluoride, zinc nitrate trihydrate,cadmium oxide, cadmium hydroxide, cadmium carbonate, cadmium methylate,cadmium propylate, cadmium chloride, cadmium bromide, cadmium fluoride,lead oxide, lead hydroxide, lead carbonate, lead ethylate, leadpentylate, lead chloride, lead fluoride lead iodide, lead nitrate,nickel oxide, nickel hydroxide, nickel carbonate, nickel chloride,nickel bromide, nickel fluoride, nickel methylate, nickel pentylate,nickel nitrate hexahydrate, cobalt oxide, cobalt hydroxide, cobaltousbromide, cobaltous chloride, cobalt butylate, cobaltous nitratehexahydrate, etc. The above metal compounds are merely illustrative ofthose useful in this invention and the invention is not to be consideredas limited to such.

U.S. Pat. No. Reissue 26,433 is expressly incorporated herein byreference for its disclosure of reactive metal compounds useful hereinand processes for utilizing these compounds in the formation of salts.Again, in applying the teachings of this patent to the presentinvention, it is only necessary to substitute the ethylene-alpha-olefinpolymer substituted mono- and dicarboxylic acid materials of thisinvention on an equivalent weight basis for the high molecular weightcarboxylic acylating agents of the reissue patent.

U.S. Pat. No. 3,271,310 discloses the preparation of metal salt of highmolecular weight carboxylic acid acylating agents, in particular alkenylsuccinic acids. The metal salts disclosed therein are acid salts,neutral salts, and basic salts. Among the illustrative reactive metalcompounds used to prepare the acidic, neutral and basic salts of thehigh molecular weight carboxylic acids disclosed in U.S. Pat. No.3,271,310 are lithium oxide, lithium hydroxide, lithium carbonate,lithium pentylate, sodium oxide, sodium hydroxide, sodium carbonate,sodium methylate, sodium propylate, sodium phenoxide, potassium oxide,potassium hydroxide, potassium carbonate, potassium methylate, silveroxide, silver carbonate, magnesium oxide, magnesium hydroxide, magnesiumcarbonate, magnesium ethylate, magnesium propylate, magnesium phenoxide,calcium oxide, calcium hydroxide, calcium carbonate, calcium methylate,calcium propylate, calcium pentylate, zinc oxide, zinc hydroxide, zinccarbonate, zinc propylate, strontium oxide, strontium hydroxide, cadmiumoxide, cadmium hydroxide, cadmium carbonate, cadmium ethylate, bariumoxide, barium hydroxide, barium hydrate, barium carbonate, bariumethylate, barium pentylate, aluminum oxide, aluminum propylate, leadoxide, lead hydroxide, lead carbonate, tin oxide, tin butylate, cobaltoxide, cobalt hydroxide, cobalt carbonate, cobalt pentylate, nickeloxide, nickel hydroxide, and nickel carbonate. The present invention isnot to be considered as limited to the use of the above metal compounds;they are presented merely to illustrate the metal compounds includedwithin the invention.

U.S. Pat. No. 3,271,310 is expressly incorporated herein by referencefor its disclosure of suitable reactive metal compounds for formingsalts of the ethylene-alpha-olefin polymer substituted mono- anddicarboxylic acid materials of this invention as well as illustrativeprocesses for preparing salts of these materials. As will be apparent,the processes of U.S. Pat. No. 3,271,310 are applicable to the polymersubstituted materials of this invention merely by substituting on anequivalent weight basis, the ethylene-alpha-olefin polymer substitutedmono- and dicarboxylic acid materials of this invention for the highmolecular weight carboxylic acids of the patent.

From the foregoing description, it is apparent that theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention can be reacted with any individual amine,alcohol, reactive metal, reactive metal compound or any combination oftwo or more of any of these; that is, for example, one or more amines,one or more alcohols, one or more reactive metals or reactive metalcompounds, or a mixture of any of these.

The mixture can be a mixture of two or more amines, a mixture of two ormore alcohols, a mixture of two or more metals or reactive metalcompounds, or a mixture of two or more components selected from aminesand alcohols, from amines and reactive metals or reactive metalcompounds, from alcohols and reactive metals compounds, or one or morecomponents from each of the amines, alcohols, and reactive metal orreactive metal compounds. Furthermore, the ethylene-alpha-olefin polymersubstituted mono- and dicarboxylic acid materials of this invention canbe reacted with the amines, alcohols, reactive metals, reactive metalcompounds, or mixtures thereof, as described above, simultaneously(concurrently) or sequentially in any order of reaction.

Canadian Patent 956,397 is expressly incorporated herein by referencefor its disclosure of procedures for reacting the ethylene-alpha-olefinpolymer substituted mono- and dicarboxylic acid materials of thisinvention with amines, alcohols, reactive metal and reactive metalcompounds, or mixtures of these, sequentially and simultaneously. Allthat is required to apply the processes of that patent to this inventionis to substitute, on an equivalent weight basis, theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention for the high molecular weight carboxylicacid acylating agents disclosed in that Canadian patent.

Carboxylic acid derivatives of this invention prepared utilizing theprocesses disclosed in the Canadian patent constitute a preferred classof carboxylic acids or carboxylic acid derivative compositions. Thefollowing Patents are also incorporated herein by reference, beingcounterparts of the incorporated Canadian patent, for the same reasonsgiven for incorporating the Canadian patent: 3,836,469; 3,836,470;3,836,471; 3,838,050; 3,838,052; 3,879,308; 3,957,854; 3,957,855. TheCanadian patent and the U.S. patents are also incorporated herein toillustrate that the amount of polyoxyalkylene alcohol demulsifierutilized in preparing dispersant/detergents from theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention is normally quite small on an equivalentbasis.

It is also pointed out that, among the more preferred carboxylicderivative compositions of this invention are those prepared accordingto the Canadian patent and corresponding U.S. patent and applicationidentified above in which the polyoxyalkylene alcohol demulsifier hasbeen omitted. In other words, a preferred class of carboxylic derivativecompositions of this invention are the various reaction products of thehigh molecular weight carboxylic acid acylating agents of the Canadianpatent with one or more amines, alcohols, and reactive metal compoundsas disclosed therein differing only in that the ethylene-alpha-olefinpolymer substituted mono- and dicarboxylic acid materials of thisinvention are substituted on an equivalent weight basis and, further,that the polyoxyalkylene alcohol demulsifier reactant is omitted.

In addition, U.S. Pat. No. 3,806,456 is expressly incorporated herein byreference for its disclosure of processes useful in preparing productsfrom the ethylene-alpha-olefin polymer substituted mono- anddicarboxylic acid materials of this invention and polyoxyalkylenepolyamines as described hereinbefore. Substitution of theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention for the high molecular weight carboxylicacid acylating agents disclosed in U.S. Pat. No. 3,806,456 on anequivalent weight basis produces compounds of similar utility furthercharacterized by the desired viscosity index improving propertiesdiscussed hereinbefore.

U.S. Pat. No. 3,576,743 is also incorporated herein by reference for itsdisclosure of a process for preparing carboxylic derivative compositionsfrom both polyhydric alcohols and amine; in particular,hydroxy-substituted primary amines. Again, substitution of theethylene-alpha-olefin polymer substituted mono- and dicarboxylic acidmaterials of this invention on an equivalent weight basis for the highmolecular carboxylic acid acylating agents disclosed in U.S. Pat. No.3,576,743 provides compositions having the desired dispersant/detergentcompositions and the V.I. improving properties already discussed.

U.S. Pat. No. 3,632,510 is expressly incorporated herein by referencefor its disclosure of processes for preparing mixed ester-metal salts.Mixed ester-metal salts derived from ethylene-alpha-olefin polymersubstituted mono- and dicarboxylic acid materials of this invention, thealcohols, and the reactive metal compounds can be prepared by followingthe processes disclosed in U.S. Pat. No. 3,632,510 but substituting, onan equivalent weight basis, the ethylene-alpha-olefin polymersubstituted mono- and dicarboxylic acid materials of this invention forthe high molecular weight carboxylic acid acylating agents of thepatent. The carboxylic acid derivative compositions thus produced alsorepresent a preferred aspect of this invention.

Finally, U.S. Pat. Nos. 3,755,169; 3,804,763; 3,868,330; and 3,948,800are expressly incorporated herein by reference for their disclosure ofhow to prepare carboxylic acid derivative compositions. By following theteachings of these patents and substituting the ethylene-alpha-olefinpolymer substituted mono- and dicarboxylic acid materials of thisinvention for the high molecular weight carboxylic acylating agents ofthe patents, a wide range of carboxylic derivative compositions withinthe scope of the present invention can be prepared.

Incorporation of so many patents is done for the sake of brevity andbecause, it is felt, that the procedures necessary to prepare thecarboxylic derivative compositions from the ethylene alpha-olefinpolymer substituted mono- and dicarboxylic acid materials and theamines, alcohols, and reactive metals and reactive metal compounds, aswell as mixtures thereof, is well within the skill of the art, such thata detailed description herein is not necessary.

A preferred group of ashless dispersants are those derived fromethylene-propylene copolymer (and diene interpolymer) substituted withsuccinic anhydride groups (referred to herein as "EPSA") and reactedwith polyethylene amines, e.g., tetraethylene pentamine, pentaethylenehexamine, polyoxyethylene and polyoxypropylene amines, e.g.,polyoxypropylene diamine, trismethylolaminomethane and pentaerythritol,and combinations thereof. One particularly preferred dispersantcombination involves a combination of (A) ethylene-propylene copolymersubstituted with succinic anhydride groups and reacted with (B) ahydroxy compound, e.g., pentaerythritol, (C) a polyoxyalkylenepolyamine, e.g., polyoxypropylene diamine, and (D) a polyalkylenepolyamine, e.g. polyethylene diamine and tetraethylene pentamine usingabout 0.3 to about 2 moles each of (B) and (D) and about 0.3 to about 2moles of (C) per mole of (A) as described in U.S. Pat. No. 3,804,763.Another preferred dispersant combination involves the combination of (A)ethylene-propylene copolymer succinic anhydride with (B) a polyalkylenepolyamine, e.g., tetraethylene pentamine, and (C) a polyhydric alcoholor polyhydroxy-substituted aliphatic primary amine, e.g.,pentaerythritol or trismethylolaminomethane as described in U.S. Pat.No. 3,632,511.

The dispersant materials of this invention are preferably characterizedby a VR' value of not greater than about 4.1, preferably not greaterthan about 4.0, e.g., from about 2.5 to 4.0, and most preferably fromabout 3.5 to 3.9. As used herein, the term "VR' value" is intended torefer to the quotient obtained by the expression (XIX): ##EQU2## whereinVIS'a is the kinematic viscosity (ASTM Method D445) of the dispersantmaterial at 100° C. in units of centistokes, and VIS'b is the coldcranking simulator (CCS) viscosity (ASTM Method D2602) at -20° C. inunits of poise, as determined at a dispersant material polymerconcentration of 2 wt. % in the reference oil as defined above forFormula IV. Preferably, the disperant materials of this invention arealso characterized by a VR'/VR_(r) ratio of not greater than about 1.11,more preferably not greater than about 1.09, still more preferably fromabout 0.7 to 1.08 and most preferably from about 0.9 to 1.05, whereinVR_(r) =3.7±0.1 for the reference oil.

Another aspect of this invention involves the post treatment of thenitrogen or ester containing dispersant materials. The process forpost-treating said nitrogen or ester containing dispersant materials isanalogous to the post-treating processes used with respect toderivatives of conventional ethylene copolymers of the prior art.Accordingly, the same reaction conditions, ratio of reactants and thelike can be used.

The nitrogen-containing dispersant materials of the instant invention asdescribed above are post-treated by contacting said nitrogen-containingdispersant materials with one or more post-treating reagents selectedfrom the group consisting of boron oxide, boron oxide hydrate, boronhalides, boron acids, esters of boron acids, carbon disulfide, sulfur,sulfur clorides, alkenyl cyanides, aldehydes, ketones, urea, thio-urea,guanidine, dicyanodiamide, hydrocarbyl phosphates, hydrocarbylphosphites, hydrocarbyl thiophosphates, hydrocarbyl thiophosphites, C₁to C₃₀ hydrocarbyl substituted succinic acids and anhydrides (e.g.,succinic anhydride, dodecyl succinic anhydride and the like), maleicanhydride (or any of the above discussed monounsaturated carboxylicreactants useful in forming the ethylene-alpha-olefinpolymer-substituted mono- and dicarboxylic acid materials employed inthis invention), phosphorus sulfides, phosphorus oxides, phosphoricacid, hydrocarbyl thiocyanates, hydrocarbyl isocyanates, hydrocarbylisothiocyantes, epoxides, episulfides, formaldehyde orformaldehyde-producing compounds plus phenols, and sulfur plus phenols.The same post-treating reagents are used with the dispersant materialsprepared from a combination of polyamines and polyols. However, when thedispersant materials are derived from polyols, and that is, when theyare esters, the post-treating reagents are usually selected from thegroup consisting of boron oxide, boron oxide hydrate, boron halides,boron acids, esters of boron acids, sulfur, sulfur chlorides, phosphorussulfides, phosphorus oxides, epoxides, and episulfides.

For example, the nitrogen containing dispersants can be treated with aboron compound selected from the class consisting of boron oxide, boronhalides, boron acids and esters of boron acids in an amount to providefrom about 0.1 atomic proportion of boron for each mole of said nitrogencomposition to about 20 atomic proportions of boron for each atomicproportion of nitrogen of said nitrogen composition. Usefully theborated dispersants of the invention contain from about 0.05 to 2.0 wt.%, e.g. 0.05 to 0.7 wt. % boron based on the total weight of saidborated nitrogen-containing dispersant compound. The boron, whichappears to be in the product as dehydrated boric acid polymers(primarily (HBO₂)₃), is believed to attach to the dispersant as aminesalts, e.g., the metaborate salt of said amine dispersants.

Treating is readily carried out by adding from about 0.05 to 4, e.g. 1to 3 wt. % (based on the weight of said nitrogen compound) of said boroncompound, preferably boric acid which is most usually added as a slurryto said nitrogen compound and heating with stirring at from about 135°C. to 190°, e.g. 140°-170° C., for from 1 to 5 hours followed bynitrogen stripping at said temperature ranges. Or, the boron treatmentcan be carried out by adding boric acid to the hot reaction mixture ofthe dicarboxylic acid material and amine while removing water.

Since post-treating processes involving the use of these post-treatingreagents is known insofar as application to reaction products of highmolecular weight carboxylic acid acylating agents of the prior art andamines and/or alcohols, further descriptions of these processes hereinis unnecessary. In order to apply the prior art processes to thecompositions of this invention, all that is necessary is that reactionconditions, ratio of reactants, and the like as described in the priorart, be applied to the novel compositions of this invention. Thefollowing U.S. patents are expressly incorporated herein by referencefor their disclosure of post-treating processes and post-treatingreagents applicable to the compositions of this invention: U.S. Pat.Nos. 3,087,936; 3,184,411; 3,185,645; 3,185,704, 3,200,107; 3,245,908;3,245,909; 3,245,910, 3,254,025; 3,256,185; 3,278,550; 3,280,034;3,281,428; 3,282,955; 3,284,410; 3,312,619; 3,338,832, 3,344,069;3,366,569; 3,367,943; 3,369,021; 3,373,111; 3,390,086; 3,403,102;3,415,750; 3,428,561; 3,458,530; 3,470,098; 3,502,677; 3,513,093;3,533,945; 3,541,012; 3,551,466; 3,558,743; 3,573,205; 3,639,242;3,652,616; 3,692,681; 3,708,522; 3,718,663; 3,749,695; 3,859,318;3,865,740; 3,865,813; 3,954,639; 4,338,205; 4,428,849; 4,686,054;4,839,070; 4,839,071; 4,839,072; 4,839,073; U.K. Pat. No.1,085,903; U.K.Pat. No. 1,162,436.

The nitrogen and/or ester containing dispersant materials of thisinvention can also be treated with polymerizable lactones (such asepsilon-caprolactone) to form dispersant adducts having the moiety --C(O)(CH₂)_(z) O!_(m) H, wherein z is a number of from 4 to 8 (e.g., 5 to7) and m has an average value of from about 0 to 100 (e.g., 0.2 to 20).The dispersants of this invention can be post-treated with a C₅ to C₉lactone, e.g., epsilon-caprolactone, by heating a mixture of thedispersant material and lactone in a reaction vessel in the absence of asolvent at a temperature of about 50° C. to about 200° C., morepreferably from about 75° C. to about 180° C, and most preferably fromabout 90° C. to about 160° C., for a sufficient period of time to effectreaction. Optionally, a solvent for the lactone, dispersant materialand/or the resulting adduct may be employed to control viscosity and/orthe reaction rates.

In one preferred embodiment, the C₅ to C₉ lactone, e.g.,epsilon-caprolactone, is reacted with a dispersant material in a 1:1mole ratio of lactone to dispersant material. In practice, the ration oflactone to dispersant material may vary considerably as a means ofcontrolling the length of the sequence of the lactone units in theadduct. For example, the mole ratio of the lactone to the dispersantmaterial may vary from about 10:1 to about 0.1:1, more preferably fromabout 5:1 to about 0.2:1, and most preferably from about 2:1 to about0.4:1. It is preferable to maintain the average degree of polymerizationof the lactone monomer below about 100, with a degree of polymerizationon the order of from about 0.2 to about 50 being preferred, and fromabout 0.2 to about 20 being more preferred. For optimum dispersantperformance, sequences of from about 1 to about 5 lactone units in a roware preferred.

Catalysts useful in the promotion of the lactone-dispersant materialreactions are selected from the group consisting of stannous octanoate,stannous hexanoate, tetrabutyl titanate, a variety of organic based acidcatalysts and amine catalysts, as described on page 266, and forward, ina book chapter authored by R. D. Lundberg and E. F. Cox, entitled"Kinetics and Mechanisms of Polymerization: Ring OpeningPolymerization", edited by Frisch and Reegen, published by Marcel Dekkerin 1969, wherein stannous octanoate is an especially preferred catalyst.The catalyst is added to the reaction mixture at a concentration levelof about 50 to about 10,000 parts per weight of catalyst per one millionparts of the total reaction mixture.

Exemplary of adducts formed by reaction of dispersant materials if thisinvention and epsilon-caprolactone are those adducts illustrated by thefollowing equation: ##STR20## wherein m and EP are as defined above. Thereactions of such lactones with dispersant materials containing nitrogenor ester groups is more completely described in U.S. Pat. Nos.4,486,326; 4,820,432; 4,828,742; 4,851,524; 4,866,135; 4,366,139;4,866,140; 4,866,141; 4,866,142, and 4,866,187, the disclosure of eachof which is hereby incorporated by reference in its entirety.

Further aspects of the present invention reside in the formation ofmetal complexes of the novel dispersant additives prepared in accordancewith this invention. Suitable metal complexes may be formed inaccordance with known techniques of employing a reactive metal ionspecies during or after the formation of the present dispersantmaterials. Complex forming metal reactants include the metal nitrates,thiocyanates, halides, carboxylates, phosphates, thio-phosphates,sulfates, and borates of transition metals such as iron, cobalt, nickel,copper, chromium, manganese, molybdenum, tungsten, ruthenium, palladium,platinum, cadmium, lead, silver, mercury, antimony and the like. Priorart disclosures of these complexing reactions may be also found in U.S.Pat. Nos. 3,306,908 and Re. 26,433, the disclosures of which are herebyincorporated by reference in their entirety.

The processes of these incorporated patents, as applied to thecompositions of this invention, and the post-treated compositions thusproduced constitute a further aspect of this invention.

As a further feature of the present invention, the (A)ethylene-alpha-olefin polymer (including diene terpolymer) substitutedmono- and di-carboxylic acid materials of this invention can be admixed,prior to, after or during being contacted with the selected nucleophilicreagant, with (B) a conventional polyolefin-substituted mono- ordicarboxylic acid material derived from any of the polyolefins discussedabove as being useful as a mixed charge with the ethylenicallyunsaturated ethylene-alpha-olefin polymers in the formation of theethylene-alpha-olefin polymer substituted mono-and di-carboxylic acidmaterials of this invention. The ethylene-alpha-olefin polymersubstituted mono- and di-carboxylic acid materials of this invention andthe polyolefin-substituted mono- or dicarboxylic acid material will begenerally admixed prior to contact with the selected selectednucleophilic reagant, e.g., alkylene polyamine. Such mixtures willgenerally employ a weight:weight ratio of ethlyene-alpha-olefin polymersubstituted mono-and di-carboxylic acid materials of this invention topolyolefin-substituted mono- or dicarboxylic acid material from about10:90 to 90:10, preferably from about 20:80 to 80:20, and morepreferably from about 40:60 to 60:40. Especially preferred are mixturesof ethylene-propylene copolymer-substituted succinic anhydride materialsof this invention and polybutyl-substituted succinic anhydride (derivedfrom polyisobutylene, poly-n-butene, or mixtures thereof, having anumber average molecular weight as described above for the aboveconventional polyolefins, e.g., 900-5,000, more usually from about 1300to 3,000). The resulting mixtures can then be contacted for reactionwith the selected nucleophilic reagent as described above for formationof dispersant materials having improved viscosity properties, whereinthe VR' of the resulting dispersant material is preferably less than theVR' of the corresponding dispersant prepared from thepolyolefin-substituted mono- or dicarboxylic acid material alone. Theresulting mixed dispersant materials can also be treated with any of theabove-described post-treatment methods for incorporation of additionalfunctional groups thereon, such as boron, hydroxy, ester, epoxy,lactone, sulfur, metals and the like, as discussed above.

OLEAGINOUS COMPOSITIONS

The dispersants of the present invention can be incorporated into alubricating oil (or a fuel) in any convenient way. Thus, thesedispersants can be added directly to the lubricating oil (or fuel) bydispersing or dissolving the same in the lubricating oil (or fuel) atthe desired level of concentration of the dispersant. Such blending intothe additional lubricating oil (or fuel) can occur at room temperatureor elevated temperatures. Alternatively, the dispersants can be blendedwith a suitable oil-soluble solvent/diluent (such as benzene, xylene,toluene, lubricating base oils and petroleum distillates, including thevarious normally liquid fuels described in detail below) to form aconcentrate, and then blending the concentrate with a lubricating oil(or fuel) to obtain the final formulation. Such dispersant concentrateswill typically contain (on an active ingredient (A.I.) basis) from about3 to about 45 wt. %, and preferably from about 10 to about 35 wt. %,dispersant additive, and typically from about 30 to 90 wt. %, preferablyfrom about 40 to 60 wt. %, base oil, based on the concentrate weight.

When the products of this invention are incorporated into crude oilrefinery process streams and other hydrocarbon fluid process streams,they function as antifoulants and will be generally used, e.g., inamounts of up to 100 ppm, e.g., 5 to 50 ppm, in the same manner as themacrocyclic polyamine additive as described in U.S. Pat. No. 4,569,750,the disclosure of which is hereby incorporated by reference, in itsentirety.

The dispersant products of the present invention possess very gooddispersant properties as measured herein in a wide variety ofenvironments. Accordingly, the dispersant products are used byincorporation and dissolution into oleaginous materials such as fuelsand lubricating oils. When the dispersant products of this invention areused in normally liquid petroleum fuels such as middle distillatesboiling from about 65° to 430° C., including kerosene, diesel fuels,home heating fuel oil, jet fuels, etc., a concentration of the additivesin the fuel in the range of typically from about 0.001 to about 0.5, andpreferably 0.005 to about 0.15 weight percent, based on the total weightof the composition, will usually be employed. The properties of suchfuels are well known as illustrated, for example, by ASTM SpecificationsD #396-73 (Fuel Oils) and D #439-73 (Gasolines) available from theAmerican Society for Testing Materials ("ASTM"), 1916 Race Street,Philadelphia, Pa. 19103.

The fuel compositions of this invention can contain, in addition to theproducts of this invention, other additives which are well known tothose of skill in the art. These can include anti-knock agents such astetraalkyl lead compounds, lead scavengers such as haloalkanes, depositpreventers or modifiers such as triaryl phosphates, dyes, cetaneimprovers, antioxidants such as 2,6-ditertiary-butyl4-methylphenol, rustinhibitors, bacteriostatic agents, gum inhibitors, metal deactivators,upper cylinder lubricants and the like.

The dispersant products of the present invention find their primaryutility in lubricating oil compositions which employ a base oil in whichthe additives re dissolved or dispersed. Such base oils may be naturalor synthetic. Base oils suitable for use in preparing the lubricatingoil compositions of the present invention include those conventionallyemployed as crankcase lubricating oils for spark-ignited andcompression-ignited internal combustion engines, such as automobile andtruck engines, marine and railroad diesel engines, and the like.Advantageous results are also achieved by employing the additivemixtures of the present invention in base oils conventionally employedin and/or adapted for use as power transmitting fluids, universaltractor fluids and hydraulic fluids, heavy duty hydraulic fluids, powersteering fluids and the like. Gear lubricants, industrial oils, pumpoils and other lubricating oil compositions can also benefit from theincorporation therein of the additive mixtures of the present invention.

These lubricating oil formulations conventionally contain severaldifferent types of additives that will supply the characteristics thatare required in the formulations. Among these types of additives areincluded viscosity index improvers, antioxidants, corrosion inhibitors,detergents, dispersants, pour point depressants, antiwear agents,friction modifiers, and other ashless dispersant (e.g., polyisobutenylsuccinimides) and borated derivatives thereof, etc.

In the preparation of lubricating oil formulations it is common practiceto introduce the additives in the form of 10 to 80 wt. %, e.g., 20 to 80wt. % active ingredient concentrates in hydrocarbon oil, e.g. minerallubricating oil, or other suitable solvent. Usually these concentratesmay be diluted with 3 to 100, e.g., 5 to 40 parts by weight oflubricating oil, per part by weight of the additive package, in formingfinished lubricants, e.g. crankcase motor oils. The purpose ofconcentrates, of course, is to make the handling of the variousmaterials less difficult and awkward as well as to facilitate solutionor dispersion in the final blend. Thus, a dispersant would be usuallyemployed in the form of a 40 to 50 wt. % concentrate, for example, in alubricating oil fraction.

The ashless dispersants of the present invention will be generally usedin admixture with a lube oil basestock, comprising an oil of lubricatingviscosity, including natural and synthetic lubricating oils and mixturesthereof.

Natural oils include animal oils and vegetable oils (e.g., castor, lardoil) liquid petroleum oils and hydrorefined, solvent-treated oracid-treated mineral lubricating oils of the paraffinic, naphthenic andmixed paraffinic-naphthenic types. Oils of lubricating viscosity derivedfrom coal or shale are also useful base oils.

Alkylene oxide polymers and interpolymers and derivatives thereof wherethe terminal hydroxyl groups have been modified by esterification,etherification, etc., constitute another class of known syntheticlubricating oils. These are exemplified by polyoxyalkylene polymersprepared by polymerization of ethylene oxide or propylene oxide, thealkyl and aryl ethers of these polyoxyalkylene polymers (e.g.,methyl-poly isopropylene glycol ether having an average molecular weightof 1000, diphenyl ether of polyethylene glycol having a molecular weightof 500-1000, diethyl ether of polypropylene glycol having a molecularweight of 1000-1500); and mono- and polycarboxylic esters thereof, forexample, the acetic acid esters, mixed C₃ -C₈ fatty acid esters and C₁₃Oxo acid diester of tetraethylene glycol.

Another suitable class of synthetic lubricating oils comprises theesters of dicarboxylic acids (e.g., phthalic acid, succinic acid, alkylsuccinic acids and alkenyl succinic acids, maleic acid, azelaic acid,suberic acid, sebasic acid, fumaric acid, adipic acid, linoleic aciddimer, malonic acid, alkylmalonic acids, alkenyl malonic acids) with avariety of alcohols (e.g., butyl alcohol, hexyl alcohol, dodecylalcohol, 2-ethylhexyl alcohol, ethylene glycol, diethylene glycolmonoether, propylene glycol). Specific examples of these esters includedibutyl adipate, di(2-ethylhexyl)sebacate, di-n-hexyl fumarate, dioctylsebacate, diisooctyl azelate, diisodecyl azelate, dioctyl phthalate,didecyl phthalate, dieicosyl sebacate, the 2-ethylhexyl diester oflinoleic acid dimer, and the complex ester formed by reacting one moleof sebacic acid with two moles of tetraethylene glycol and two moles of2-ethylhexanoic acid.

Esters useful as synthetic oils also include those made from C₅ to C₁₂monocarboxylic acids and polyols and polyol ethers such as neopentylglycol, trimethylolpropane, pentaerythritol, dipentaerythritol andtripentaerythritol.

Silicon-based oils such as the polyalkyl-, polyaryl-, polyalkoxy-, orpolyaryloxysiloxane oils and silicate oils comprise another useful classof synthetic lubricants; they include tetraethyl silicate,tetraisopropyl silicate, tetra-(2-ethylhexyl)silicate,tetra-(4-methyl-2-ethylhexyl)silicate,tetra-(p-tert-butylphenyl)silicate, hexa-(4-methyl-2-pentoxy)disiloxane,poly(methyl)-siloxanes and poly(methylphenyl)siloxanes. Other syntheticlubricating oils include liquid esters of phosphorus-containing acids(e.g., tricresyl phosphate, trioctyl phosphate, diethyl ester ofdecylphosphonic acid) and polymeric tetrahydrofurans.

Unrefined, refined and rerefined oils can be used in the lubricants ofthe present invention. Unrefined oils are those obtained directly from anatural or synthetic source without further purification treatment. Forexample, a shale oil obtained directly from retorting operations, apetroleum oil obtained directly from distillation or ester oil obtaineddirectly from an esterification process and used without furthertreatment would be an unrefined oil. Refined oils are similar to theunrefined oils except they have been further treated in one or morepurification steps to improve one or more properties. Many suchpurification techniques, such as distillation, solvent extraction, acidor base extraction, filtration and percolation are known to thoseskilled in the art. Rerefined oils are obtained by processes similar tothose used to obtain refined oils applied to refined oils which havebeen already used in service. Such rerefined oils are also known asreclaimed or reprocessed oils and often are additionally processed bytechniques for removal of spent additives and oil breakdown products.

Metal containing rust inhibitors and/or detergents are frequently usedwith ashless dispersants. Such detergents and rust inhibitors includethe metal salts of sulphonic acids, alkyl phenols, sulphurized alkylphenols, alkyl salicylates, naphthenates, and other oil soluble mono-and di-carboxylic acids. Highly basic, that is overbased metal saltswhich are frequently used as detergents appear particularly prone tointeraction with the ashless dispersant. Usually these metal containingrust inhibitors and detergents are used in lubricating oil in amounts ofabout 0.01 to 10, e.g. 0.1 to 5 wt. %, based on the weight of the totallubricating composition. Marine diesel lubricating oils typically employsuch metal-containing rust inhibitors and detergents in amounts of up toabout 20 wt. %.

Highly basic alkaline earth metal sulfonates are frequently used asdetergents. They are usually produced by heating a mixture comprising anoil-soluble sulfonate or alkaryl sulfonic acid, with an excess ofalkaline earth metal compound above that required for completeneutralization of any sulfonic acid present and thereafter forming adispersed carbonate complex by reacting the excess metal with carbondioxide to provide the desired overbasing. The sulfonic acids aretypically obtained by the sulfonation of alkyl substituted aromatichydrocarbons such as those obtained from the fractionation of petroleumby distillation and/or extraction or by the alkylation of aromatichydrocarbons as for example those obtained by alkylating benzene,toluene, xylene, naphthalene, diphenyl and the halogen derivatives suchas chlorobenzene, chlorotoluene and chloronaphthalene. The alkylationmay be carried out in the presence of a catalyst with alkylating agentshaving from about 3 to more than 30 carbon atoms. For examplehaloparaffins, olefins obtained by dehydrogenation of paraffins,polyolefins produced from ethylene, propylene, etc. are all suitable.The alkaryl sulfonates usually contain from about 9 to about 70 or morecarbon atoms, preferably from about 16 to about 50 carbon atoms peralkyl substituted aromatic moiety.

The alkaline earth metal compounds which may be used in neutralizingthese alkaryl sulfonic acids to provide the sulfonates includes theoxides and hydroxides, alkoxides, carbonates, carboxylate, sulfide,hydrosulfide, nitrate, borates and ethers of magnesium, calcium, andbarium. Examples are calcium oxide, calcium hydroxide, magnesium acetateand magnesium borate. As noted, the alkaline earth metal compound isused in excess of that required to complete neutralization of thealkaryl sulfonic acids.

Generally, the amount ranges from about 100 to 220%, although it ispreferred to use at least 125%, of the stoichiometric amount of metalrequired for complete neutralization.

Various other preparations of basic alkaline earth metal alkarylsulfonates are known, such as U.S. Pat. Nos. 3,150,088 and 3,150,089wherein overbasing is accomplished by hydrolysis of analkoxide-carbonate complex with the alkaryl sulfonate in a hydrocarbonsolvent-diluent oil.

A preferred alkaline earth sulfonate additive is magnesium alkylaromatic sulfonate having a total base number ranging from about 300 toabout 400 with the magnesium sulfonate content ranging from about 25 toabout 32 wt. %, based upon the total weight of the additive systemdispersed in mineral lubricating oil.

Neutral metal sulfonates are frequently used as rust inhibitors.Polyvalent metal alkyl salicylate and naphthenate materials are knownadditives for lubricating oil compositions to improve their hightemperature performance and to counteract deposition of carbonaceousmatter on pistons (U.S. Pat. No. 2,744,069). An increase in reservebasicity of the polyvalent metal alkyl salicylates and naphthenates canbe realized by utilizing alkaline earth metal, e.g. calcium, salts ofmixtures of C₈ -C₂₆ alkyl salicylates and phenates (see U.S. Pat. No.2,744,069) or polyvalent metal salts of alkyl salicyclic acids, saidacids obtained from the alkylation of phenols followed by phenation,carboxylation and hydrolysis (U.S. Pat. No. 3,704,315) which could thenbe converted into highly basic salts by techniques generally known andused for such conversion. The reserve basicity of these metal-containingrust inhibitors is usefully at TBN levels of between about 60 and 150.Included with the useful polyvalent metal salicylate and naphthenatematerials are the methylene and sulfur bridged materials which arereadily derived from alkyl substituted salicylic or naphthenic acids ormixtures of either or both with alkyl substituted phenols. Basicsulfurized salicylates and a method for their preparation is shown inU.S. Pat. No. 3,595,791. Such materials include alkaline earth metal,particularly magnesium, calcium, strontium and barium salts of aromaticacids having the general formula:

    HOOC--ArR.sub.1 --Xy(ArR.sub.1 OH)n                        (XX)

where Ar is an aryl radical of 1 to 6 rings, R₁ is an alkyl group havingfrom about 8 to 50 carbon atoms, preferably 12 to 30 carbon atoms(optimally about 12), X is a sulfur (--S--) or methylene (--CH₂ --)bridge, y is a number from 0 to 4 and n is a number from 0 to 4.

Preparation of the overbased methylene bridged salicylate-phenate saltis readily carried out by conventional techniques such as by alkylationof a phenol followed by phenation, carboxylation, hydrolysis, methylenebridging a coupling agent such as an alkylene dihalide followed by saltformation concurrent with carbonation. An overbased calcium salt of amethylene bridged phenol-salicylic acid of the general formula (XXI):##STR21## with a TBN of 60 to 150 is highly useful in this invention.

The sulfurized metal phenates can be considered the "metal salt of aphenol sulfide" which thus refers to a metal salt whether neutral orbasic, of a compound typified by the general formula (XXII): ##STR22##where x=1 or 2, n=0, 1 or 2; or a polymeric form of such a compound,where R is an alkyl radical, n and x are each integers from 1 to 4, andthe average number of carbon atoms in all of the R groups is at leastabout 9 in order to ensure adequate solubility in oil. The individual Rgroups may each contain from 5 to 40, preferably 8 to 20, carbon atoms.The metal salt is prepared by reacting an alkyl phenol sulfide with asufficient quantity of metal containing material to impart the desiredalkalinity to the sulfurized metal phenate.

Regardless of the manner in which they are prepared, the sulfurizedalkyl phenols which are useful generally contain from about 2 to about14% by weight, preferably about 4 to about 12 wt. % sulfur based on theweight of sulfurized alkyl phenol.

The sulfurized alkyl phenol may be converted by reaction with a metalcontaining material including oxides, hydroxides and complexes in anamount sufficient to neutralize said phenol and, if desired, to overbasethe product to a desired alkalinity by procedures well known in the art.Preferred is a process of neutralization utilizing a solution of metalin a glycol ether.

The neutral or normal sulfurized metal phenates are those in which theratio of metal to phenol nucleus is about 1:2. The "overbased" or"basic" sulfurized metal phenates are sulfurized metal phenates whereinthe ratio of metal to phenol is greater than that of stoichiometric,e.g. basic sulfurized metal dodecyl phenate has a metal content up toand greater than 100% in excess of the metal present in thecorresponding normal sulfurized metal phenates wherein the excess metalis produced in oil-soluble or dispersible form (as by reaction withCO₂). The overbased sulfurized metal phenates desirably have a TBN valueof at least 150, e.g. from 200 to 300.

Magnesium and calcium containing additives although beneficial in otherrespects can increase the tendency of the lubricating oil to oxidize.This is especially true of the highly basic sulphonates.

According to a preferred embodiment the invention therefore provides acrankcase lubricating composition also containing from 2 to 8000 partsper million of calcium or magnesium.

The magnesium and/or calcium is generally present as basic or neutraldetergents such as the sulphonates and phenates, our preferred additivesare the neutral or basic magnesium or calcium sulphonates. Preferablythe oils contain from 500 to 5000 parts per million of calcium ormagnesium. Basic magnesium and calcium sulphonates are preferred.

A particular advantage of the novel dispersants of the present inventionis use with V.I improvers to form multi-grade automobile enginelubricating oils. Viscosity modifiers impart high and low temperatureoperability to the lubricating oil and permit it to remain relativelyviscous at elevated temperatures and also exhibit acceptable viscosityor fluidity at low temperatures. Viscosity modifiers are generally highmolecular weight hydrocarbon polymers including polyesters. Theviscosity modifiers may also be derivatized to include other propertiesor functions, such as the addition of dispersancy properties. These oilsoluble viscosity modifying polymers will generally have number averagemolecular weights of from 10³ to 10⁶, preferably 10⁴ to 10⁶, e.g.,20,000 to 250,000, as determined by gel permeation chromatography orosmometry.

Examples of suitable hydrocarbon polymers include homopolymers andcopolymers of two or more monomers of C₂ to C₃₀, e.g. C₂ to C₈ olefins,including both alpha olefins and internal olefins, which may be straightor branched, aliphatic, aromatic, alkyl-aromatic, cycloaliphatic, etc.Frequently they will be of ethylene with C₃ to C₃₀ olefins, particularlypreferred being the copolymers of ethylene and propylene. Other polymerscan be used such as polyisobutylenes, homopolymers and copolymers of C₆and higher alpha olefins, atactic polypropylene, hydrogenated polymersand copolymers and terpolymers of styrene, e.g., with isoprene and/orbutadiene and hydrogenated derivatives thereof. The polymer may bedegraded in molecular weight, for example by mastication, extrusion,oxidation or thermal degradation, and it may be oxidized and containoxygen. Also included are derivatized polymers such as post-graftedinterpolymers of ethylene-propylene with an active monomer such asmaleic anhydride which may be further reacted with an alcohol, or amine,e.g. an alkylene polyamine or hydroxy amine, e.g. see U.S. Pat. Nos.4,089,794; 4,160,739; 4,137,185; or copolymers of ethylene and propylenereacted or grafted with nitrogen compounds such as shown in U.S. Pat.Nos. 4,068,056; 4,068,058; 4,146,489 and 4,149,984.

The preferred hydrocarbon polymers are ethylene copolymers containingfrom 15 to 90 wt. % ethylene, preferably 30 to 80 wt. % of ethylene and10 to 85 wt. %, preferably 20 to 70 wt. % of one or more C₃ to C₂₈,preferably C₃ to C₁₈, more preferably C₃ to C₈, alpha-olefins. While notessential, such copolymers preferably have a degree of crystallinity ofless than 25 wt. %, as determined by X-ray and differential scanningcalorimetry. Copolymers of ethylene and propylene are most preferred.Other alpha-olefins suitable in place of propylene to form thecopolymer, or to be used in combination with ethylene and propylene, toform a terpolymer, tetrapolymer, etc., include 1-butene, 1-pentene,1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, etc.; also branchedchain alpha-olefins, such as 4-methyl-1-pentene, 4-methyl-1-hexene,5-methylpentene-1, 4,4-dimethyl-1-pentene, and 6-methylheptene-1, etc.,and mixtures thereof.

Terpolymers, tetrapolymers, etc., of ethylene, said C₃₋₂₈ alpha-olefin,and a non-conjugated diolefin or mixtures of such diolefins may also beused. The amount of the non-conjugated diolefin generally ranges fromabout 0.5 to 20 mole percent, preferably from about 1 to about 7 molepercent, based on the total amount of ethylene and alpha-olefin present.

The polyester V.I. improvers are generally polymers of esters ofethylenically unsaturated C₃ to C₈ mono- and dicarboxylic acids such asmethacrylic and acrylic acids, maleic acid, maleic anhydride, fumaricacid, etc.

Examples of unsaturated esters that may be used include those ofaliphatic saturated mono alcohols of at least 1 carbon atom andpreferably of from 12 to 20 carbon atoms, such as decyl acrylate, laurylacrylate, stearyl acrylate, eicosanyl acrylate, docosanyl acrylate,decyl methacrylate, diamyl fumarate, lauryl methacrylate, cetylmethacrylate, stearyl methacrylate, and the like and mixtures thereof.

Other esters include the vinyl alcohol esters of C₂ to C₂₂ fatty or monocarboxylic acids, preferably saturated such as vinyl acetate, vinyllaurate, vinyl palmitate, vinyl stearate, vinyl oleate, and the like andmixtures thereof. Copolymers of vinyl alcohol esters with unsaturatedacid esters such as the copolymer of vinyl acetate with dialkylfumarates, can also be used.

The esters may be copolymerized with still other unsaturated monomerssuch as olefins, e.g. 0.2 to 5 moles of C₂ -C₂₀ aliphatic or aromaticolefin per mole of unsaturated ester, or per mole of unsaturated acid oranhydride followed by esterification. For example, copolymers of styrenewith maleic anhydride esterified with alcohols and amines are known,e.g., see U.S. Pat. No. 3,702,300.

Such ester polymers may be grafted with, or the ester copolymerizedwith, polymerizable unsaturated nitrogen-containing monomers to impartdispersancy to the V.I. improvers. Examples of suitable unsaturatednitrogen-containing monomers include those containing 4 to 20 carbonatoms such as amino substituted olefins asp-(beta-diethylamino-ethyl)styrene; basic nitrogen-containingheterocycles carrying a polymerizable ethylenically unsaturatedsubstituent, e.g. the vinyl pyridines and the vinyl alkyl pyridines suchas 2-vinyl-5-ethyl pyridine, 2-methyl-5-vinyl pyridine,2-vinyl-pyridine, 4-vinylpyridine, 3-vinyl-pyridine,3-methyl-5-vinyl-pyridine, 4-methyl-2-vinyl-pyridine,4-ethyl-2-vinyl-pyridine and 2-butyl-1-5-vinyl-pyridine and the like.

N-vinyl lactams are also suitable, e.g. N-vinyl pyrrolidones or N-vinylpiperidones.

The vinyl pyrrolidones are preferred and are exemplified by N-vinylpyrrolidone, N-(1-methylvinyl) pyrrolidone, N-vinyl-5-methylpyrrolidone, N-vinyl-3, 3-dimethylpyrrolidone, N-vinyl-5-ethylpyrrolidone, etc.

Dihydrocarbyl dithiophosphate metal salts are frequently used asanti-wear agents and also provide antioxidant activity. The zinc saltsare most commonly used in lubricating oil in amounts of 0.1 to 10,preferably 0.2 to 2 wt. %, based upon the total weight of thelubricating oil composition. They may be prepared in accordance withknown techniques by first forming a dithiophosphoric acid, usually byreaction of an alcohol or a phenol with P₂ S₅ and then neutralizing thedithiophosphoric acid with a suitable zinc compound.

Mixtures of alcohols may be used including mixtures of primary andsecondary alcohols, secondary generally for imparting improved anti-wearproperties, with primary giving improved thermal stability properties.Mixtures of the two are particularly useful. In general, any basic orneutral zinc compound could be used but the oxides, hydroxides andcarbonates are most generally employed. Commercial additives frequentlycontain an excess of zinc due to use of an excess of the basic zinccompound in the neutralization reaction.

The zinc dihydrocarbyl dithiophosphates useful in the present inventionare oil soluble salts of dihydrocarbyl esters of dithiophosphoric acidsand may be represented by the following formula: ##STR23## wherein R andR' may be the same or different hydrocarbyl radicals containing from 1to 18, preferably 2 to 12 carbon atoms and including radicals such asalkyl, alkenyl, aryl, aralkyl, alkaryl and cycloaliphatic radicals.Particularly preferred as R and R' groups are alkyl groups of 2 to 8carbon atoms. Thus, the radicals may, for example, be ethyl, n-propyl,i-propyl, n-butyl, i-butyl, sec-butyl, amyl, n-hexyl, i-hexyl, n-octyl,decyl, dodecyl, octadecyl, 2-ethylhexyl, phenyl, butylphenyl,cyclohexyl, methylcyclopentyl, propenyl, butenyl, etc. In order toobtain oil solubility, the total number of carbon atoms (i.e., R and R'in formula XXIII) in the dithiophosphoric acid will generally be about 5or greater.

The antioxidants useful in this invention include oil soluble coppercompounds. The copper may be blended into the oil as any suitable oilsoluble copper compound. By oil soluble we mean the compound is oilsoluble under normal blending conditions in the oil or additive package.The copper compound may be in the cuprous or cupric form. The copper maybe in the form of the copper dihydrocarbyl thio- or dithio-phosphateswherein copper may be substituted for zinc in the compounds andreactions described above although one mole of cuprous or cupric oxidemay be reacted with one or two moles of the dithiophosphoric acid,respectively. Alternatively the copper may be added as the copper saltof a synthetic or natural carboxylic acid. Examples include C₁₀ to C₁₈fatty acids such as stearic or palmitic, but unsaturated acids such asoleic or branched carboxylic acids such as napthenic acids of molecularweight from 200 to 500 or synthetic carboxylic acids are preferredbecause of the improved handling and solubility properties of theresulting copper carboxylates. Also useful are oil soluble copperdithiocarbamates of the general formula (RR'NCSS)_(n) Cu, where n is 1or 2 and R and R' are the same or different hydrocarbyl radicalscontaining from 1 to 18 and preferably 2 to 12 carbon atoms andincluding radicals such as alkyl, alkenyl, aryl, aralkyl, alkaryl andcycloaliphatic radicals. Particularly preferred as R and R' groups arealkyl groups of 2 to 8 carbon atoms. Thus, the radicals may, forexample, be ethyl, n-propyl, i-propyl, n-butyl, i-butyl, sec-butyl,amyl, n-hexyl, i-hexyl, n-heptyl, n-octyl, decyl, dodecyl, octadecyl,2-ethylhexyl, phenyl, butylphenyl, cyclohexyl, methylcyclopentyl,propenyl, butenyl, etc. In order to obtain oil solubility, the totalnumber of carbon atoms (i.e., R and R') will generally be about 5 orgreater. Copper sulphonates, phenates, and acetylacetonates may also beused.

Exemplary of useful copper compounds are copper (Cu^(I) and/or Cu^(II))salts of alkenyl succinic acids or anhydrides. The salts themselves maybe basic, neutral or acidic. They may be formed by reacting (a) any ofthe materials above discussed ashless dispersants which have at leastone free carboxylic acid (or anhydride) group with (b) a reactive metalcompound. Suitable acid (or anhydride) reactive metal compounds includethose such as cupric or cuprous hydroxides, oxides, acetates, borates,and carbonates or basic copper carbonate.

Examples of the metal salts of this invention are Cu salts ofpolyisobutenyl succinic anhydride (hereinafter referred to as Cu-PIBSA),and Cu salts of polyisobutenyl succinic acid. Preferably, the selectedmetal employed is its divalent form, e.g., Cu⁺². The preferredsubstrates are polyalkenyl succinic acids in which the alkenyl group hasa molecular weight greater than about 700. The alkenyl group desirablyhas a M_(n) from about 900 to 1400, and up to 2500, with a M_(n) ofabout 950 being most preferred. Especially preferred is polyisobutylenesuccinic acid (PIBSA). These materials may desirably be dissolved in asolvent, such as a mineral oil, and heated in the presence of a watersolution (or slurry) of the metal bearing material. Heating may takeplace between 70° and about 200° C. Temperatures of 110° to 140° C. areentirely adequate. It may be necessary, depending upon the saltproduced, not to allow the reaction to remain at a temperature aboveabout 140° C. for an extended period of time, e.g., longer than 5 hours,or decomposition of the salt may occur.

The copper antioxidants (e.g., Cu-PIBSA, Cu-oleate, or mixtures thereof)will be generally employed in an amount of from about 50-500 ppm byweight of the metal, in the final lubricating composition.

The copper antioxidants used in this invention are inexpensive and areeffective at low concentrations and therefore do not add substantiallyto the cost of the product. The results obtained are frequently betterthan those obtained with previously used antioxidants, which areexpensive and used in higher concentrations. In the amounts employed,the copper compounds do not interfere with the performance of othercomponents of the lubricating composition, in many instances, completelysatisfactory results are obtained when the copper compound is the soleantioxidant in addition to the ZDDP. The copper compounds can beutilized to replace part or all of the need for supplementaryantioxidants. Thus, for particularly severe conditions it may bedesirable to include a supplementary, conventional antioxidant. However,the amounts of supplementary antioxidant required are small, far lessthan the amount required in the absence of the copper compound.

While any effective amount of the copper antioxidant can be incorporatedinto the lubricating oil composition, it is contemplated that sucheffective amounts be sufficient to provide said lube oil compositionwith an amount of the copper antioxidant of from about 5 to 500 (morepreferably 10 to 200, still more preferably 10 to 180, and mostpreferably 20 to 130 (e.g., 90 to 120)) part per million of added copperbased on the weight of the lubricating oil composition. Of course, thepreferred amount may depend amongst other factors on the quality of thebasestock lubricating oil.

Corrosion inhibitors, also known as anti-corrosive agents, reduce thedegradation of the metallic parts contacted by the lubricating oilcomposition. Illustrative of corrosion inhibitors are phosphosulfurizedhydrocarbons and the products obtained by reaction of aphosphosulfurized hydrocarbon with an alkaline earth metal oxide orhydroxide, preferably in the presence of an alkylated phenol or of analkylphenol thioester, and also preferably in the presence of carbondioxide. Phosphosulfurized hydrocarbons are prepared by reacting asuitable hydrocarbon such as a terpene, a heavy petroleum fraction of aC₂ to C₆ olefin polymer such as polyisobutylene, with from 5 to 30weight percent of a sulfide of phosphorus for 1/2 to 15 hours, at atemperature in the range of 65° to 315° C. Neutralization of thephosphosulfurized hydrocarbon may be effected in the manner taught inU.S. Pat. No. 1,969,324.

Oxidation inhibitors reduce the tendency of mineral oils to deterioratein service which deterioration can be evidenced by the products ofoxidation such as sludge and varnish-like deposits on the metal surfacesand by viscosity growth. Such oxidation inhibitors include alkalineearth metal salts of alkylphenolthioesters having preferably C₅ to C₁₂alkyl side chains, calcium nonylphenol sulfide, barium t-octylphenylsulfide, dioctylphenylamine, phenylalphanaphthylamine, phosphosulfurizedor sulfurized hydrocarbons, etc.

Friction modifiers serve to impart the proper friction characteristicsto lubricating oil compositions such as automatic transmission fluids.

Representative examples of suitable friction modifiers are found in U.S.Pat. No. 3,933,659 which discloses fatty acid esters and amides; U.S.Pat. No. 4,176,074 which describes molybdenum complexes ofpolyisobutenyl succinic anhydride-amino alkanols; U.S. Pat. No.4,105,571 which discloses glycerol esters of dimerized fatty acids; U.S.Pat. No. 3,779,928 which discloses alkane phosphonic acid salts; U.S.Pat. No. 3,778,375 which discloses reaction products of a phosphonatewith an oleamide; U.S. Pat. No. 3,852,205 which disclosesS-carboxy-alkylene hydrocarbyl succinimide, S-carboxyalkylenehydrocarbyl succinamic acid and mixtures thereof; U.S. Pat. No.3,879,306 which discloses N-(hydroxyalkyl) alkenyl-succinamic acids orsuccinimides; U.S. Pat. No. 3,932,290 which discloses reaction productsof di-(lower alkyl) phosphites and epoxides; and U.S. Pat. No. 4,028,258which discloses the alkylene oxide adduct of phosphosulfurizedN-(hydroxyalkyl) alkenyl succinimides. The disclosures of the abovereferences are herein incorporated by reference. The most preferredfriction modifiers are glycerol mono and dioleates, and succinateesters, or metal salts thereof, of hydrocarbyl substituted succinicacids or anhydrides and thiobis alkanols such as described in U.S. Pat.No. 4,344,853.

Pour point depressants lower the temperature at which the lubricatingoil will flow or can be poured. Such depressants are well known. Typicalof those additives which usefully optimize the low temperature fluidityof the fluid are C₈ -C₁₈ dialkylfumarate vinyl acetate copolymers,poly-methacrylates, and wax naphthalene.

Foam control can be provided by an antifoamant of the polysiloxane type,e.g. silicone oil and polydimethyl siloxane.

Organic, oil-soluble compounds useful as rust inhibitors in thisinvention comprise nonionic surfactants such as polyoxyalkylene polyolsand esters thereof, and anionic surfactants such as salts of alkylsulfonic acids. Such anti-rust compounds are known and can be made byconventional means. Nonionic surfactants, useful as anti-rust additivesin the oleaginous compositions of this invention, usually owe theirsurfactant properties to a number of weak stabilizing groups such asether linkages. Nonionic anti-rust agents containing ether linkages canbe made by alkoxylating organic substrates containing active hydrogenswith an excess of the lower alkylene oxides (such as ethylene andpropylene oxides) until the desired number of alkoxy groups have beenplaced in the molecule.

The preferred rust inhibitors are polyoxyalkylene polyols andderivatives thereof. This class of materials are commercially availablefrom various sources: Pluronic Polyols from Wyandotte ChemicalsCorporation; Polyglycol 112-2, a liquid trio derived from ethylene oxideand propylene oxide available from Dow Chemical Co.; and Tergitol,dodecylphenyl or monophenyl polyethylene glycol ethers, and Ucon,polyalkylene glycols and derivatives, both available from Union CarbideCorp. These are but a few of the commercial products suitable as rustinhibitors in the improved composition of the present invention.

In addition to the polyols per se, the esters thereof obtained byreacting the polyols with various carboxylic acids are also suitable.Acids useful in preparing these esters are lauric acid, stearic acid,succinic acid, and alkyl- or alkenyl-substituted succinic acids whereinthe alkyl-or alkenyl group contains up to about twenty carbon atoms.

The preferred polyols are prepared as block polymers. Thus, ahydroxy-substituted compound, R--(OH)n (wherein n is 1 to 6, and R isthe residue of a mono- or polyhydric alcohol, phenol, naphthol, etc.) isreacted with propylene oxide to form a hydrophobic base. This base isthen reacted with ethylene oxide to provide a hydrophylic portionresulting in a molecule having both hydrophobic and hydrophylicportions. The relative sizes of these portions can be adjusted byregulating the ratio of reactants, time of reaction, etc., as is obviousto those skilled in the art. Thus it is within the skill of the art toprepare polyols whose molecules are characterized by hydrophobic andhydrophylic moieties which are present in a ratio rendering rustinhibitors suitable for use in any lubricant composition regardless ofdifferences in the base oils and the presence of other additives.

If more oil-solubility is needed in a given lubricating composition, thehydrophobic portion can be increased and/or the hydrophylic portiondecreased. If greater oil-in-water emulsion breaking ability isrequired, the hydrophylic and/or hydrophobic portions can be adjusted toaccomplish this.

Compounds illustrative of R--(OH)n include alkylene polyols such as thealkylene glycols, alkylene triols, alkylene tetrols, etc., such asethylene glycol, propylene glycol, glycerol, pentaerythritol, sorbitol,mannitol, and the like. Aromatic hydroxy compounds such as alkylatedmono- and polyhydric phenols and naphthols can also be used, e.g.,heptylphenol, dodecylphenol, etc.

Other suitable demulsifiers include the esters disclosed in U.S. Pat.Nos. 3,098,827 and 2,674,619.

The liquid polyols available from Wyandotte Chemical Co. under the namePluronic Polyols and other similar polyols are particularly well suitedas rust inhibitors. These Pluronic Polyols correspond to the formula:##STR24## wherein x,y, and z are integers greater than 1 such that the--H₂ CH₂ O-- groups comprise from about 10% to about 40% by weight ofthe total molecular weight of the glycol, the average molecule weight ofsaid glycol being from about 1000 to about 5000. These products areprepared by first condensing propylene oxide with propylene glycol toproduce the hydrophobic base ##STR25## This condensation product is thentreated with ethylene oxide to add hydrophylic portions to both ends ofthe molecule. For best results, the ethylene oxide units should comprisefrom about 10 to about 40% by weight of the molecule. Those productswherein the molecular weight of the polyol is from about 2500 to 4500and the ethylene oxide units comprise from about 10% to about 15% byweight of the molecule are particularly suitable. The polyols having amolecular weight of about 4000 with about 10% attributable to (CH₂ CH₂O) units are particularly good. Also useful are alkoxylated fattyamines, amides, alcohols and the like, including such alkoxylated fattyacid derivatives treated with C₉ to C₁₆ alkyl-substituted phenols (suchas the mono- and di-heptyl, octyl, nonyl, decyl, undecyl, dodecyl andtridecyl phenols), as described in U.S. Pat. No. 3,849,501, which isalso hereby incorporated by reference in its entirety.

These compositions of our invention may also contain other additivessuch as those previously described, and other metal containingadditives, for example, those containing barium and sodium.

The lubricating composition of the present invention may also includecopper lead bearing corrosion inhibitors. Typically such compounds arethe thiadiazole polysulphides containing from 5 to 50 carbon atoms,their derivatives and polymers thereof. Preferred materials are thederivatives of 1,3,4-thiadiazoles such as those described in U.S. Pat.Nos. 2,719,125; 2,719,126; and 3,087,932; especially preferred is thecompound 2,5 bis(t-octadithio)-1,3,4-thiadiazole commercially availableas Amoco 150. Other similar materials also suitable are described inU.S. Pat. Nos. 3,821,236; 3,904,537; 4,097,387; 4,107,059; 4,136,043;4,188,299; and 4,193,882.

Other suitable additives are the thio and polythio sulphenamides ofthiadiazoles such as those described in U.K. Patent Specification1,560,830. When these compounds are included in the lubricatingcomposition, we prefer that they be present in an amount from 0.01 to10, preferably 0.1 to 5.0 weight percent based on the weight of thecomposition.

Some of these numerous additives can provide a multiplicity of effects,e.g., a dispersant-oxidation inhibitor. This approach is well known andneed not be further elaborated herein.

Compositions when containing these conventional additives are typicallyblended into the base oil in amounts effective to provide their normalattendant function. Representative effective amounts of such additives(as the respective active ingredients) in the fully formulated oil areillustrated as follows:

    ______________________________________                                                         Wt. % A.I.  Wt. % A.I.                                       Compositions     (Preferred) (Broad)                                          ______________________________________                                        Viscosity Modifier                                                                             0.01-4      0.01-12                                          Detergents       0.01.-3     0.01-20                                          Corrosion Inhibitor                                                                            0.01-1.5    .01-5                                            Oxidation Inhibitor                                                                            0.01-1.5    .01-5                                            Dispersant       0.1-8       .1-20                                            Pour Point Depressant                                                                          0.01-1.5    .01-5                                            Anti-Foaming Agents                                                                            0.001-0.15  .001-3                                           Anti-Wear Agents 0.001-1.5   .001-5                                           Friction Modifiers                                                                             0.01-1.5    .01-5                                            Mineral Oil Base Balance     Balance                                          ______________________________________                                    

When other additives are employed, it may be desirable, although notnecessary, to prepare additive concentrates comprising concentratedsolutions or dispersions of the novel dispersants of this invention (inconcentrate amounts hereinabove described), together with one or more ofsaid other additives (said concentrate when constituting an additivemixture being referred to herein as an additive-package) whereby severaladditives can be added simultaneously to the base oil to form thelubricating oil composition. Dissolution of the additive concentrateinto the lubricating oil may be facilitated by solvents and by mixingaccompanied with mild heating, but this is not essential. Theconcentrate or additive-package will typically be formulated to containthe additives in proper amounts to provide the desired concentration inthe final formulation when the additive-package is combined with apredetermined amount of base lubricant. Thus, the dispersants of thepresent invention can be added to small amounts of base oil or othercompatible solvents along with other desirable additives to formadditive-packages containing active ingredients in collective amounts oftypically from about 2.5 to about 90%, and preferably from about 15 toabout 75%, and most preferably from about 25 to about 60% by weightadditives in the appropriate proportions with the remainder being baseoil.

The final formulations may employ typically about 10 wt. % of theadditive-package with the remainder being base oil.

All of said weight percents expressed herein (unless otherwiseindicated) are based on active ingredient (A.I.) content of theadditive, and/or upon the total weight of any additive-package, orformulation which will be the sum of the A.I. weight of each additiveplus the weight of total oil or diluent.

This invention will be further understood by reference to the followingexamples, wherein all parts are parts by weight, unless otherwise notedand which include preferred embodiments of the invention. In theExamples, SA:PIB and SA:EP-polymer ratios are based upon the total PIBand EP-polymer, respectively, charged to the reactor as startingmaterial, i.e., both the PIB and EP-polymer which reacts and the PIB andEP-polymer which remains unreacted. In the Examples, wt. % ethylene inthe polymers was determined by FTIR (ASTM Method D3900). In theExamples, the "reference oil" was as defined above for Formula IV.

EXAMPLE 1 Preparation of Ethylene-Propylene Copolymer

A 1 liter Zipperclave reactor (Autoclave Engineers) equipped with awater jacket for temperature control, with a septum inlet for syringeinjection of catalyst, and with a supply of purified nitrogen, liquidpropylene, and ethylene was used used in these polymerizations. Thereactor was cleaned with hot toluene and then was purged well with drynitrogen at 100° C. The reactor was cooled to 25° C. and 10.0 cc of a4.0 wt % toluene solution of methylalumoxane was injected along with 100cc of distilled toluene at 0 psig under nitrogen. Liquid propylenemonomer (200 cc) was added from a calibrated burette at 25° C. Thereactor contents were stirred and heated to 115° C. at which point thereactor pressure was 375 psig. 1.00 cc of a toluene solution ofbis(n-butylcyclopentadienyl) zirconium dichloride (1.00 mg) was injectedand ethylene at a pressure of 405 psig was immediately supplied.Ethylene was fed on pressure demand in order to keep the system pressureat 405 psig. The rate of ethylene flow was recorded continuously duringthe course of the polymerization. The reaction was continued for 15minutes after which the reaction was stopped by rapidly depressuring andcooling the reactor to 25° C. The polymer product was collected and thetoluene solvent was evaporated in an air stream. The polymer weight wasdetermined to be 103.1 gms, and the polymer was analyzed bysize-exclusion chromatography and found to contain 68 wt % ethylene andto have a number average molecular weight of 1100, a weight averagemolecular weight of 5400 and a polydispersity of 4.9. The polymerproduct was found to contain 2.5 wppm Zr and 1.75 wppm Cl.

EXAMPLE 2 Preparation of Ethylene-Propylene Copolymer

The polymerization was performed as in Example 1 except that the reactortemperature was maintained at 100° C. and 1.00 mg ofdimethyl-silyldicyclopentadienyl zirconium dichloride was used ascatalyst instead of bis(n-butylcyclopentadienyl) zirconium dichloride.The reactor pressure was maintained at 380 psig by a regulated ethylenesupply. The yield of the copolymer was 111.2 gms and the polymer wasdetermined to contain the ethylene content indicated in Table I and tohave a number average molecular weight of 1390, a weight averagemolecular weight of 4030 and polydispersity of 2.9. The polymer productwas found to contain 2.0 wppm Zr and 1.5 wppm Cl.

EXAMPLE 3 Preparation of Ethylene-Propylene Copolymer

The polymerization was performed as in Example 2 except that the reactortemperature was maintained at 90° C. and 270 cc of liquid propylene wascharged. The reactor pressure was maintained by a regulated ethylenesupply. The yield of the copolymer was 16.3 gms and the polymer wasdetermined to contain the ethylene content indicated in Table I and tohave a number average molecular weight of 1750, a weight averagemolecular weight of 4960 and polydispersity of 2.8. The polymer productwas found to contain 16 wppm Zr and 10 wppm Cl.

EXAMPLE 4 Preparation of Ethylene-Propylene Copolymer

The polymerization was performed as in Example 3 except that the reactortemperature was maintained at 80° C. The reactor pressure was maintainedat 365 psig by a regulated ethylene supply for 1 hour. The yield of thecopolymer was 234 gms and the polymer was determined to have a numberaverage molecular weight of 2710, a weight average molecular weight of7980 and polydispersity of 2.9. The polymer product was found to containthe ethylene content indicated in Table I and to contain 1.0 wppm Zr and0.7 wppm Cl.

EXAMPLE 5 Preparation of Ethylene Butene-1 Copolymer

The polymerization was performed as in Example 3 except that 270 cc ofliquid butene-1 was charged instead of the propylene. The reactorpressure was maintained at 167 psig by a regulated ethylene supply. Theyield of the copolymer was 176.6 gms and the polymer was determined tohave a number average molecular weight of 860, a weight averagemolecular weight of 2710 and polydispersity of 3.1. The polymer productwas found to contain 1.5 wppm Zr and 1.1 wppm Cl.

EXAMPLES 6-10 Preparation of Ethylene-Propylene Copolymer SubstitutedSuccinic Anhydride (EPSA)

In a series of runs, the selected moles of the EP copolymers prepared asabove and pulverized maleic anhydride are charged under dry N₂ atatmospheric pressure to a 100 ml. pressure reactor equipped with astirrer and a thermocouple and heated by means of an electric heatingmantle. No added solvent or diluent for the reactants is employed.Rather the reaction is conducted in the melt. In each run, the reactionmixture is heated to 70° C. and the reactor is gently purged with dry N₂by bubbling through the liquid reaction mass for 15 minutes. The purgingis then ceased and the reactor temperature is raised to 220° C. and keptat that temperature under autogenous pressure for 4 hours whilestirring. The liquid reaction mixture is then cooled to about 60° C.,and transferred to a glass beaker. Dry gaseous nitrogen is passedthrough the liquid to strip off unreacted maleic anhydride at about 140°C. until no trace of maleic anhydride is detected with IR. The liquidproduct containing the EPSA and unreacted EP is analyzed for succinicanhydride by the following titration technique: a 2 g. sample of thepolymer is dissolved in a solvent comprising 80 ml of THF, 6 ml ofpyridine and 0.3 ml of water and titrated with a methanol solution oftetrabutyl ammonium hydroxide using thymol blue to a color end point.The acidity is calculated from the milliliters of base solution used.The product is also observed to determine the presence of any sediment.

In Example 11, the procedure of Example 6 is repeated except that thepolymer was charged comprised a 50:50 wt:wt mixture of theethylene-propylene copolymer prepared as in Example 4 (M_(n) =2710), andthe polyisobutylene polymer which is employed in Comparative Example 13(M_(n) =1300). The data thereby obtained are the mole ratio of polymerand maleic anhydride charged, and the data thereby obtained aresummarized in Table I.

                                      TABLE I                                     __________________________________________________________________________    Feed                                                                                      Copolymer                                                                            Mol.  Titration of Succinic Acid                                       As Pre-                                                                              Ratio of                                                                            in the EPSA (or EP/PIB-SA)                                       pared In                                                                             of EP to MA                                                                         Product, Meq/gram                                    Example                                                                            EP Copolymer                                                                         Example                                                                              Charged                                                                             Theor.                                                                            Found                                                                             % Conv. (3)                                                                         Sediment (4)                           __________________________________________________________________________    6    M.sub.n = 1100                                                                       1      1/1.2 0.91                                                                              0.73                                                                              80.3  moderate                                    68 wt. % C.sub.2.sup.═                                               7    M.sub.n = 1390                                                                       2      1/1.2 0.72                                                                              0.65                                                                              89.3  moderate                                    56 wt. % C.sub.2.sup.═                                               8    M.sub.n = 1750                                                                       3      1/1.2 0.57                                                                              0.43                                                                              75.4  none                                        59 wt. % C.sub.2.sup.═                                               9    M.sub.n = 2710                                                                       4      1/1.2 0.37                                                                              0.31                                                                              83.8  none                                        55 wt. % C.sub.2.sup.═                                               10   M.sub.n = 2710                                                                       4      1/3.2 0.37                                                                              0.56                                                                              150   slight                                      55 wt. % C.sub.2.sup.═                                               11   (1)    4(EP)  (2)   0.6 0.52                                                                              86.7  some                                               Comp.13 (PIB)                                                     __________________________________________________________________________     NOTES:                                                                        EP  ethylenepropylene copolymer; PIB = polyisobutylene; MA = maleic           anhydride.                                                                    (1) EP M.sub.n = 2710, 55 wt. % C.sub.2.sup.═ ; PIB M.sub.n = 1200.       (2) (EP + PIB)/MA = 1.0:1.2 mole ratio charged.                               (3) Based on (theoretical  found) meq/gm SA.                                  (4) Low amounts of sediment not quantified.                              

COMPARATIVE EXAMPLES 12-14

To determine the degree of sediment formed in maleic anhydride reactionswith conventional polyisobutylene polymers and conventionalethylene-propylene copolymers, the above procedure is repeated in aseries of runs. The polyisobutylene polymer employed in ComparativeExample 12 comprises Parapol 1300 polymer (Exxon Chemical Americas), andthe polyisobutylene polymer employed in Comparative Example 13 comprisesreactive polyisobutylene (ultra Vis30; BP Chemicals), having about 0.58mole of terminal double bonds per mole of polymer (as determined by NMR)and a molecular weight distribution of about 3.0 (based on GPC). Theethylene-propylene copolymer of Comparative Example 14 (42 wt %ethylene, 58 wt % propylene; M_(n) =1060; M_(w) =1903) is prepared byconventional Ziegler Natta catalysis of ethylene and propylene using acatalyst system comprising VOCl₃ and aluminum sesquichloride, with H₂ asmolecular weight control. The data thereby obtained are summarized inTable II.

                                      TABLE II                                    __________________________________________________________________________    Feed             Titration of Succinic Acid in                                Compara-   Mol. Ratio                                                                          the PIBSA (or EPSA) Reaction                                 tive Polymer                                                                             of PIB                                                                              Product Mixture, Meq/gram                                    Example                                                                            (Mn)  or EP to MA                                                                         Theor.                                                                            Found                                                                             % Conv. (1)                                                                         Sediment (2)                                   __________________________________________________________________________    12   PIB (1300)                                                                          1/1.2 0.77                                                                              0.34                                                                              44.2  heavy (2)                                      13   PIB (1200)                                                                          1/1.2 0.83                                                                              0.47                                                                              56.4  heavy (2)                                      14   EP (1060)                                                                           1/1.2 0.94                                                                              0.15                                                                              16.0  none                                           __________________________________________________________________________     Notes:                                                                        EP  ethylenepropylene copolymer; PIB = polyisobutylene; MA = maleic           anhydride.                                                                    (1) Calculated as in Table I.                                                 (2) Sediment (1.24 wt. % and 0.36 wt. % based on PIB charged) found in        Examples 12 and 13, respectively, as hexane insoluble solids on reaction      vessel bottom.                                                           

The above results illustrate the surprisingly reduced sediment formationand high conversions achieved in the thermal "ene" reaction of maleicanhydride and the ethylene-propylene copolymers in accordance with theprocess of this invention in Examples 6-10, as compared to conventionalpolyisobutylene polymers (Comparative Examples 12-13) and conventionalethylene-propylene copolymers (Comparative Example 14).

EXAMPLES 15-20; COMPARATIVE EXAMPLES 21-22

Preparation of Polyamine Dispersants

A series of dispersant materials are prepared employing the EPSAproducts prepared as in Examples 9 and 10, the mixed (EP/PIB)SA productof Example 11, the PIBSA product of Comparative Example 14, and variousblends of the above PIBSA and EPSA products.

The succinic acid anhydride substituted polymers are dissolved in anequal amount by weight of a mineral oil, S150N. To the polymer solutionis added a mixture of polyethylene polyamines having the averagecomposition corresponding to tetraethylene pentamine and containingabout 32.6 wt % N (PAM) and the mixture is heated to 140° C. undernitrogen while stirring for about 2 to 4 hours. In each run, the molarratio of total polymer to polyamine in terms of succinic acidequivalents to PAM charged is 2 to 1.

Viscosities of the resulting dispersant solutions are determined.Results of the viscometric studies are summarized in Table III below.

                                      TABLE III                                   __________________________________________________________________________                   SA-   % N Estimated                                                           Polymer/                                                                            in the Viscometrics                                           Polymer in                                                                              Amine Mole                                                                          Product                                                                              KV 100° C.                                                                   CCS                                         Example                                                                            S150N,    Ratio (1)                                                                           Solution                                                                             cSt   -20° C., p                                                                  VR' (2)                                __________________________________________________________________________    15   EPSA from Ex. 10                                                                        2/1   0.88   7.44  23.14                                                                              3.11                                   16   A Mix of 20%                                                                            2/1   0.78   6.38  24.58                                                                              3.85                                        EPSA from Ex. 10                                                              and 80% PIBSA                                                                 from Comp. Ex.                                                           17   A Mix of 50% EPSA                                                                       2/1   0.79   6.75  24.29                                                                              3.60                                        from Ex. 10 and 50%                                                           PIBSA from Comp.                                                              Ex. 14                                                                   18   A Mix of 50% PIBSA                                                                      2/1   0.66   7.52  28.26                                                                              3.76                                        from Comp. Ex. 13                                                             and 50% EPSA from                                                             Ex. 9                                                                    19   A Mix of 50% PIBSA                                                                      2/1   0.80   8.11  28.86                                                                              3.56                                        from Comp. Ex. 13                                                             and 50% EPSA from                                                             Ex. 10                                                                   20   (A 50/50 Mix of EP                                                                      2/1   0.82   6.43  23.42                                                                              3.64                                        and PIB) SA from                                                              Ex. 11                                                                   Comp. 21                                                                           PIBSA from Comp.                                                                        2/1   0.73   6.20  24.65                                                                              4.0                                         Ex. 14                                                                   Comp. 22                                                                           Control   None  0      5.19  19.20                                                                              3.70                                   __________________________________________________________________________     Notes:                                                                        (1) Mole ratio of polymer (calculated in terms of mole of contained           succinic acid/anhydride groups) per mole of polyamine charged.                (2) VR' =  CCS, -20° C., poise!/ KV 100° C. cSt!.          

EXAMPLES 25-26: COMPARATIVE EXAMPLE 27

A series of dispersant blends are prepared employing the dispersantproduct solutions made as in Example 15 and Comparative Example 21, andthe viscometrics measured, as summarized in Table IV below:

                  TABLE IV                                                        ______________________________________                                                        Viscometrics                                                  Blend of Dispersant                                                                             KV 100° C.                                                                       CCS                                               Example                                                                              Dispersant Wt. %   cStcSt  -20° C., p.                                                                    VR'                                 ______________________________________                                        25     Ex, 15     20      6.44    24.80   3.85                                       Comp.Ex.21 80                                                          26     Ex. 15     50      6.82    24.29   3.56                                       Comp.Ex.21 50                                                          Comp.27                                                                              Comp.Ex.21 --      6.20    24.65   4.0                                 --     Reference Oil                                                                             0      5.19    19.20   3.70                                ______________________________________                                    

The lower VR' values signify a better viscometric balance that isdesirable for dispersant to have. Results show that the viscometricbehavior of PIB-based dispersants can be improved, as indicated by lowerVR' values, by means of blending with the EP-copolymer based dispersantsof this invention and also by making polyamine dispersants from a mix ofPIBSA and EPSA dispersant intermediates. Moreover, the above resultsindicate that the VR' values for the dispersant product solutions ofExamples 25-26, unlike the comparative dispersant of Comparative Example27, are lower than the VR_(r) value for the reference oil itself.

EXAMPLE 28

Ethylene-propylene copolymer (M_(n) =1100) prepared as in Example 1 isreacted thermally with maleic anhydride as in Example 6 to give an EPSAproduct (% AI.54.5) which is diluted with an equal amount of S150N togive a 50 wt. % polymer solution. To 25 g of the solution, 0.75 g of thePAM (wt % N=32.6) is added dropwise while stirring and light N₂ spargingat 140° C. for 2 hours followed by nitrogen stripping for an hour at140° C.

The resulting composition is then tested for sludge inhibition (via theSIB test) and varnish inhibition (via the VIB test), as described below.

The SIB test has been found, after a large number of evaluations, to bean excellent test for assessing the dispersing power of lubricating oildispersant additives.

The medium chosen for the SIB test is a used crankcase minerallubricating oil composition having an original viscosity of about 325SUS at 38₋₋ C that had been used in a taxicab that is driven generallyfor short trips only, thereby causing a buildup of a high concentrationof sludge precursors. The oil that is used contains only a refined basemineral lubricating oil, a viscosity index improver, a pour pointdepressant and zinc dialkyldithiophosphate anti-wear additive. The oilcontains no sludge dispersant. A quantity of such used oil is acquiredby draining and refilling the taxicab crankcase at 1000-2000 mileintervals.

The SIB test is conducted in the following manner: the aforesaid usedcrankcase oil, which is milky brown in color, is freed of sludge bycentrifuging for one hour at about 39,000 gravities (gs.). The resultingclear bright red supernatant oil is then decanted from the insolublesludge particles thereby separated out. However, the supernatant oilstill contains oil-soluble sludge precursors which on heating under theconditions employed by this test will tend to form additionaloil-insoluble deposits of sludge. The sludge inhibiting properties ofthe additives being tested are determined by adding to portions of thesupernatant used oil, a small amount, such as 0.5, 1 or 2 weightpercent, of the particular additive being tested. Ten grams of eachblend being tested are placed in a stainless steel centrifuge tube andare heated at 135° C. for 16 hours in the presence of air. Following theheating, the tube containing the oil being tested is cooled and thencentrifuged for about 30 minutes at room temperature at about 39,000 gs.Any deposits of new sludge that form in this step are separated from theoil by decanting the supernatant oil and then carefully washing thesludge deposits with 25 ml of heptane to remove all remaining oil fromthe sludge and further centrifuging. The weight of the new solid sludgethat has been formed in the test, in milligrams, is determined by dryingthe residue and weighing it. The results are reported as amount ofprecipitated sludge in comparison with the precipitated sludge of ablank not containing any additional additive, which blank is normalizedto a rating of 10. The less new sludge precipitated in the presence ofthe additive, the lower the SIB value and the more effective is theadditive as a sludge dispersant. In other words, if the additive giveshalf as much precipitated sludge as the blank, then it would be rated5.0 since the blank will be normalized to 10.

The VIB test is used to determine varnish inhibition. Here, the testsample consists of 10 grams of lubricating oil containing a small amountof the additive being tested. The test oil to which the additive isadmixed is of the same type as used in the above-described SIB test. Theten gram sample is heat soaked overnight at about 140° C. and thereaftercentrifuged to remove the sludge. The supernatant fluid of the sample issubjected to heat cycling from about 150° C. to room temperature over aperiod of 3.5 hours at a frequency of about 2 cycles per minute. Duringthe heating phase, gas which was a mixture of about 0.7 volume percentSO₂, 1.4 volume percent NO and balance air is bubbled through the testsample. During the cooling phase, water vapor is bubbled through thetest sample. At the end of the test period, which testing cycle can berepeated as necessary to determine the inhibiting effect of anyadditive, the wall surfaces of the test flask in which the sample iscontained are visually evaluated as to the varnish inhibition. Theamount of varnish imposed on the walls is rated to values of from 1 to11 with the higher number being the greater amount of varnish, incomparison with a blank with no additive that was rated 11.

10.00 grams of SIB test oil are mixed with 0.05 grams of the products ofthe Examples as described in Table II and tested in the aforedescribedSIB and VIB tests.

The test results are summarized below in Table V.

                  TABLE V                                                         ______________________________________                                               wt %    SIB,   VIB  KV, 100° C.,                                                                    CCS,                                      Example                                                                              A.I.    mg     rating                                                                             cs       -20° C. p                                                                     VR'                                ______________________________________                                        28     28.3    7.54   2.3  6.47     22.61  3.50                               Control A                                                                            0       10.0   10.0 5.19     19.20  3.70                               (1)                                                                           Control B                                                                            45      4.74   4    6.22     25.40  4.08                               (2)                                                                           Control C                                                                            32      5.43   7    5.89     24.12  4.10                               (3)                                                                           ______________________________________                                         Notes:                                                                        (1) Blank S150N oil, no dispersant.                                           (2) Polyisobutylene succinimide prepared from 2250 M.sub.n PIB.               (3) Polyisobutylene succinimide prepared from 1300 M.sub.n PIB.          

EXAMPLES 29-34

The procedure of Example 28 is repeated in a series of runs to prepareadditional dispersant product solutions. The results thereby obtained,and the EPSA's employed, are summarized in Table VI.

                                      TABLE VI                                    __________________________________________________________________________          EPSA                                                                          Product as                                                                             SA-Polymer/PAM      KV  CCS                                    Example                                                                             Prepared in                                                                         EP Mole     Wt. %                                                                             SIB                                                                              VIB 100° C.                                                                    -20° C.                         No.   Ex. No.                                                                             M.sub.n                                                                          Ratio(1) N(2)                                                                              (mg)                                                                             Rating                                                                            cSt p   VR'                                __________________________________________________________________________    29    6     1100                                                                             1.6      1.25                                                                              3.08                                                                             3   6.84                                                                              23.79                                                                             3.5                                30    7     1390                                                                             1.6      1.22                                                                              1.79                                                                             4-5 6.09                                                                              24.23                                                                             4.0                                31    8     1750                                                                             1.6      0.83                                                                              4.36                                                                             4   6.60                                                                              24.30                                                                             3.7                                32    9     2710                                                                             1.6      0.59                                                                              5.64                                                                             3   6.89                                                                              24.23                                                                             3.5                                33    8     1750                                                                             2.0      0.75                                                                              -- --  6.62                                                                              23.63                                                                             3.6                                34    10    2710                                                                             2.0      0.88                                                                              -- --  7.44                                                                              23.14                                                                             3.11                               S150N Oil                                                                           --    -- --       --  10 11  5.19                                                                              19.2                                                                              3.7                                __________________________________________________________________________     Notes:                                                                        (1) Mole ratio of polymer (calculated in terms of mole of contained           succinic acid/anhydride groups) per mole of polyamine charged.                (2) Estimated wt. % N in the dispersant material product solutions.      

EXAMPLE 35

The procedure of Example 6 is repeated except that 1 mole ofethylene-butene-1 copolymer (M_(n) =860) prepared as in Example 5 isemployed instead of the ethylene-propylene copolymer. The ethylenebutene copolymer-substituted succinic anhydride (EBSA) product therebyobtained is found to contain about 76 wt % active ingredient EBSA andless than about 1 wppm of chlorine and to have a VR ratio of 3.9 (KV at100° C.=5.77 cSt; CCS at -20° C.=22.63 poise).

EXAMPLES 36-39

In a separate series of runs, additional dispersants are prepared byemploying the EPSA products of Examples 6, 7, 8 and 9 and the EBSAproducts of Example 35.

An amido amine ("AA") is prepared by reacting tetraethylene pentamine(TEPA) with methyl acrylate at a 1.5:1 TEPA:methyl acrylate molar ratio,to form a product mixture containing 29.3 wt. % total N. 6.1 wt. %primary N, and about 25 wt. % unreacted TEPA.

A mixture of 10 parts by weight of the EPSA (or EBSA) product formed inthe indicated Example and 10 parts of S150N mineral oil are heated to150° C. under N₂. Then the desired amount of amido-amine prepared asabove are added dropwise while stirring and light nitrogen sparging. Themixture is nitrogen stripped at 150° C. for 3 hours and then filtered.The dispersant product solution is found to have the nitrogen contentand kinematic viscosity reported in Table VII.

Each dispersant product solution is then tested as described in Examples29-34 in the SIB and VIB tests. The results thereby obtained are alsoset forth in Table VII.

                  TABLE VII                                                       ______________________________________                                        Example No.                                                                              36      37       38    39     40                                   ______________________________________                                        EPSA as in Ex.                                                                           6       7        8     9      --                                   EP M.sub.n 1100    1390     1750  2710   --                                   EBSA as in Ex.                                                                           --      --       --    --     35                                   EB M.sub.n --      --       --    --     860                                  Dispersant (1)                                                                SA/AA (2)  1.2     1.2      1.2   1.2    1.2                                  Wt. % N (3)                                                                              1.66    1.41     0.98  0.70   1.28                                 Wt. % AI   42      45       43.4  35.5   --                                   SIB, mg    2.7     1.13     3.18  4.51   0.8                                  VIB rating 3       3-4      4     4      4-5                                  KV, 100° C., cSt                                                                  6.76    6.08     6.60  6.92   6.12                                 CCS, -20° C., p                                                                   22.49   23.06    23.62 23.95  24.00                                VR', p/cSt 3.3     3.8      3.6   3.5    3.9                                  VR'/VR.sub.r (4)                                                                         0.89    1.03     0.97  0.95   1.05                                 ______________________________________                                         NOTES:                                                                        (1) Dispersant product admixed with equal weight of S150N oil.                (2) Mole ratio of EPSA (or EBSA), calculated as moles of SA (succinic         anhydride) per equivalent of primary amine.                                   (3) Estimated N content of dispersant product.                                (4) VR.sub.r = 3.7                                                       

EXAMPLE 40

About 73.5 grams Uniroyal Trilene® 65ethylene/propylene/di-cyclopentadiene semiliquid terpolymer having aBrookfield viscosity of 67,000 centipoise at 100° C., 9.0 wt. %cyclopentadiene, and an ethylene:propylene monomer ratio of 48/52 wasdissolved in 76.4 grams 150N oil in a 300 ml Parr reactor. About 9.8grams maleic anhydride was added; the reactor was N₂ purged and heatedat 250° C. for eight hours. The product was heated in a kugelrohr at180° C. and 0.1 mm Hg to remove excess maleic anhydride.

The saponification equivalent of the purified product was 48 mg KOH pergram (96 KVH/gram on active ingredient basis).

About 16.2 grams of the above maleated product in 19 grams xylene washeated with 2.04 grams dimethyl aminopropyl amine at 60° C. for twohours. The excess xylene and amine were partially removed by N₂ purge at160° C. and purified in a Kugelrohr at 160° C. and 0.4 mm Hg.

Elemental analysis indicated 2.128 wt. % nitrogen for the polymerproduct.

We claim:
 1. A functionalized polymer comprising anethylene/alpha-olefin/diene interpolymer substituted withmonounsaturated mono- or dicarboxylic acid-producing moieties, saidinterpolymer having (i) monomer units derived from ethylene, at leastone alpha-olefin of the formula H₂ C═CHR¹ wherein R¹ is a C₁ -C₁₈ alkylgroup, and at least one diene monomer; (ii) a M_(n) of about 300-20,000;(iii) at least about 30% of its chains with ethenylidene terminalunsaturation; and (iv) less than 5 wt. % polymer fraction of M_(n) lessthan about 300;said functionalized polymer having a VR value of lessthan about 4.1.
 2. The functionalized polymer of claim 1 wherein saidinterpolymer is functionalized by "ene" reaction.
 3. The functionalizedpolymer of claim 1 wherein said acid-producing moieties are C₃ -C₁₀monounsaturated monocarboxylic acid-producing moieties, C₄ -C₁₀monounsaturated dicarboxylic acid-producing moieties, or derivativesthereof.
 4. The functionalized polymer of claim 1 wherein saidinterpolymer has a molar ethylene content of about 20-80%.
 5. Thefunctionalized polymer of claim 1 wherein said alpha-olefin is propyleneor butene.
 6. The functionalized polymer of claim 1 wherein saidacid-producing moieties are maleic anhydride or derived therefrom. 7.The functionalized polymer of claim 1 wherein said at least one dienemonomer comprises at least one of cyclopentadiene,5-ethylidene-2-norbornene, 1,4-hexadiene, vinyl norbornene,norbornadiene, and methyl hexadiene.
 8. A lubricating oil concentratecontaining about 10-80 wt. % of the functionalized polymer of claim 1.9. A lubricating oil composition containing about 5-70 wt. % of thefunctionalized polymer of claim 1.